HALDEN Pipe Inner Wall Weld Overlay Cladding Solution
Automatic TIG Hot Wire Pipe Inner Wall Cladding Machine for Long Tube Weld Overlay
HALDEN automatic TIG hot wire pipe inner wall cladding machines are designed for corrosion-resistant weld overlay inside long pipes, seamless tubes, forged tubes and pressure-related pipe components. The system combines TIG welding quality, hot wire deposition efficiency, automatic arc voltage control, pipe rotation and long-reach welding torch guidance to produce stable internal overlay layers for oil and gas, chemical, valve, pressure vessel and pipeline industries.
What Is a Pipe Inner Wall Cladding Machine?
A pipe inner wall cladding machine is an automated weld overlay system used to deposit corrosion-resistant or wear-resistant alloy layers on the internal surface of long pipes and tubes. Instead of manufacturing the entire pipe from expensive alloy material, the base pipe can be made from carbon steel or low-alloy steel, while the internal surface receives a high-performance alloy overlay.
For long pipe applications, the machine must solve several practical problems at the same time: long torch reach, stable pipe rotation, accurate arc length control, reliable wire feeding, weld pool visibility, water-cooled torch protection and consistent layer-by-layer overlay quality.
Long Pipe Capability
Designed for internal cladding of long tubes and pipes up to 12,000mm reference length.
Hot Wire TIG Quality
Combines GTAW weld cleanliness with higher deposition efficiency from hot wire feeding.
Low-Dilution Overlay
Suitable for corrosion-resistant alloy cladding where final chemistry and dilution control matter.
100% Inspection Ready
Designed for demanding quality requirements such as 100% UT layering and 100% PT inspection.
HALDEN Long Tube Inner Wall TIG Hot Wire Cladding System
The system is designed for long tube inner wall anti-corrosion welding. The base tube is driven and rotated by a hollow chuck. The welding torch is positioned and guided into the pipe by a long-reach torch mechanism, wire rope pull system and guide equipment. During welding, the torch remains stable while the pipe rotates in 1G position.
This configuration is especially useful for pipe manufacturers, oilfield equipment suppliers, pressure component fabricators and corrosion-resistant piping projects where long internal surfaces require uniform alloy overlay.
Hollow Chuck Pipe Rotation
The pipe is driven by the end hollow chuck, while the welding gun stays in position for stable 1G internal cladding.
Long-Reach Welding Torch
A long torch system supports internal cladding of pipe lengths up to 12.5m reference capability.
AVC Arc Voltage Control
Automatic arc pressure / arc voltage tracking helps correct torch distance and stabilize bead formation.
Technical Parameters
The following parameters are organized from the reference automatic TIG/GTAW pipe inner wall cladding machine data. HALDEN can adjust the final configuration according to pipe diameter, length, weight, overlay alloy, inspection requirement and production capacity.
| Item | Reference Specification | Technical Meaning |
|---|---|---|
| Model | PCS-850-TTST-12M | Reference model for long pipe inner wall cladding. |
| Welding Process | Automatic TIG Hot Wire | Automated GTAW overlay with hot wire feeding. |
| Power Source Type | DC Type Inverter | Stable DC inverter TIG power for precision overlay welding. |
| Welder Current | 5–450A | Main welding current range for different pipe materials and cladding conditions. |
| Welder Duty Cycle | 450A 80%; 420A 100% | Reference continuous operation capability for long cladding cycles. |
| Hot Wire Current | 5–200A | Controls filler wire preheating and deposition efficiency. |
| Hot Wire Duty Cycle | 200A 60%; 100A 100% | Reference duty cycle for hot wire power operation. |
| Open Circuit Voltage | 80V | Power source open-circuit voltage reference. |
| Input Voltage | 3 × 400V (-25% +20%), 50/60Hz | Industrial three-phase input voltage requirement. |
| Input Power | 80KVA | Workshop electrical supply should be confirmed before installation. |
| AVC Accuracy | ±0.2V | Arc voltage control accuracy for stable torch height and bead consistency. |
| Recommended Peak Current | 150–280A | Practical current range for many hot wire TIG overlay applications. |
| Overlay Processing Diameter | φ120mm after cladding to φ850mm | Applicable internal pipe cladding diameter range. |
| Maximum Pipe Length | Up to 12,000mm | Suitable for long pipe and tube internal overlay. |
| Loading Bearing | 20 metric tons | Machine support capacity for heavy pipe workpieces. |
| Wire Diameter | 1.2 / 1.6mm | Wire size selected according to alloy, deposition rate and bead control. |
| Tungsten Diameter | 4.0mm; 4.8mm optional | Tungsten selection depends on current and long-duration welding stability. |
| Gas Flow Rate | 12–20L/min | Shielding gas reference for internal overlay welding. |
| Arc Starting | HF / Contact | Arc start mode options for different process settings. |
| Single Layer Thickness | 1–3mm | Overlay can be built by single or multiple layers depending on final clad requirement. |
| Deposit Rate | 4.8kg/h reference; max. 4.5kg/h also listed in application data | Reference deposition productivity for hot wire TIG cladding. |
| Welding Speed | Max. 600mm/min reference | Actual speed depends on alloy, thickness, bead width and inspection requirement. |
Main System Components
A long pipe inner wall cladding system must be evaluated as a complete automation line. Welding power, hot wire power, torch guidance, hollow chuck drive, roller frame, AVC, water cooling, camera monitoring and controller software all affect final overlay quality.
| Component | Reference Configuration | Function |
|---|---|---|
| Main TIG Power Source | EWM TETRIX 452DC Ethernet/IP HF Unit | Provides stable DC pulse TIG arc for weld overlay cladding. |
| Hot Wire Power Source | EWM TETRIX 200 Hot Wire Power | Preheats filler wire to improve deposition efficiency and process stability. |
| Welding Head | Long-reach internal welding gun with water cooling | Performs internal pipe cladding inside long tubes and supports continuous welding. |
| Pipe Drive System | End hollow chuck rotation | Rotates the pipe while the welding gun stays positioned inside the bore. |
| Guidance System | Wire rope pull and guide equipment | Positions the welding gun along the pipe inner wall and supports long-distance travel. |
| Welding Swing Mechanism | Precision swing mechanism | Controls bead oscillation and overlay width for layer consistency. |
| Roller Frame | Adjustable-height steel roller frame | Supports long and heavy pipes during rotation and cladding. |
| Monitoring Camera | Water-cooled weld camera with TCP/IP communication | Allows monitoring of internal weld overlay conditions during operation. |
| Control Software | Touch & retract, online adjust, AVC, actual value visualization, remote support, bore-to-bore, data logger | Supports process control, adjustment, visualization and production data management. |
Pipe Materials and Overlay Wires
Pipe inner wall cladding is usually selected when the pipe body needs strength and cost control, while the internal surface needs corrosion resistance, sour service resistance, chemical resistance or special alloy performance.
| Category | Reference Materials | Application Meaning |
|---|---|---|
| Base Pipe Materials | 5L Gr.B, X52, X60, X65, stainless steel, CrMo steel and similar pipe materials. | Common for oil and gas pipelines, pressure pipes, process piping and heavy-duty industrial tubes. |
| Nickel Alloy Wires | ERNiCrMo-3, ERNiFeCr-1, ERNi1. | Used for corrosion-resistant internal overlay in severe chemical, oil and gas environments. |
| Stainless / Duplex Wires | ER316L, ER2209. | Used for stainless or duplex corrosion-resistant internal cladding requirements. |
| Cobalt Alloy Wires | ERCCoCr-E, ERCCoCr-A. | Used when wear resistance, galling resistance or high-temperature surface properties are required. |
| Copper-Nickel Wires | ERCuNi. | Used for selected marine, seawater and corrosion-resistant applications. |
Quality Control for Pipe Inner Wall Cladding
For pipe internal weld overlay, buyers normally care about final alloy chemistry, thickness, dilution, surface defects, interlayer quality and inspection pass rate. Long pipe cladding also requires stable monitoring because the welding position is inside the pipe and cannot be inspected visually like an external weld.
100% UT Layering
Layer-by-layer ultrasonic testing can be required to verify internal soundness and overlay integrity.
100% PT
Liquid penetrant testing helps detect surface-breaking defects after cladding and machining.
AVC Stability
Arc voltage control helps maintain consistent torch distance and bead shape during long bore cladding.
Water-Cooled Torch
Forced circulating water cooling protects the welding gun during long-duration continuous welding.
Camera Monitoring
A water-cooled weld camera allows the operator to monitor internal overlay quality during production.
Data Logging
Production data records support process traceability, quality control and future optimization.
Typical Applications
This equipment is mainly used for long tube inner wall anti-corrosion welding. It is suitable for industries where internal corrosion protection, weld overlay quality and long pipe capability are important.
Hot-Rolled Steel Pipes
Internal alloy overlay for pipeline and industrial pipe applications.
Seamless Steel Pipes
Corrosion-resistant internal cladding for pressure and process pipe service.
Forging Tubes
Overlay cladding for forged tubular components and special pipe sections.
Oil and Gas Pipes
Internal cladding for sour service, corrosive media and high-value pipeline systems.
Chemical Process Piping
Nickel alloy or stainless overlay for pipes exposed to corrosive chemical media.
Pressure Vessel Tubes
Internal cladding for pressure-related tubular components and vessel pipe sections.
HALDEN Customized Pipe Inner Wall Cladding Support
HALDEN can review your pipe drawing, internal diameter, length, wall thickness, base material, overlay alloy, required clad thickness and inspection standard before recommending a suitable pipe inner wall cladding system. The final solution can be configured for different pipe diameter ranges, long tube lengths, heavy loading capacity and production requirements.
Long Bore Cladding
For internal overlay of long pipes, seamless tubes and forged tubular components.
Hot Wire TIG Process
For clean, low-dilution corrosion-resistant overlay with higher deposition efficiency.
Monitoring & Control
AVC, camera monitoring, remote support, data logging and online adjustment options.
Turnkey Machine Design
Power source, hot wire source, pipe rotation, guide system, roller frame and cooling system.
Buyer-Critical Information Before Quotation
To recommend the correct automatic TIG pipe inner wall cladding machine, HALDEN needs detailed pipe and overlay information. This helps avoid insufficient torch reach, wrong diameter range, undersized load capacity or unsuitable cladding process design.
| Information Needed | Examples | Why It Matters |
|---|---|---|
| Pipe Drawing | PDF, DWG, STEP, pipe section drawing, cladding map. | Determines diameter range, torch reach, overlay path and machine layout. |
| Pipe Diameter | OD, ID before cladding, ID after cladding, pipe roundness tolerance. | Determines torch size, minimum bore capability and roller/chuck design. |
| Pipe Length | 3,000mm, 6,000mm, 12,000mm or customized pipe length. | Determines torch reach, guide system, floor space and machine frame length. |
| Pipe Weight | Single pipe weight, max weight, support point requirement. | Determines chuck, roller frame, drive system and safety margin. |
| Base Pipe Material | 5L Gr.B, X52, X60, X65, stainless steel, CrMo steel or customer grade. | Affects preheat, welding parameters, dilution and final overlay chemistry. |
| Overlay Alloy | ERNiCrMo-3, ERNiFeCr-1, ER316L, ER2209, ERCCoCr alloy, ERNi1, ERCuNi. | Determines hot wire parameters, layer design and corrosion-resistant performance. |
| Inspection Requirement | 100% UT layering, 100% PT, PMI, ferrite, chemical analysis, customer standard. | Affects process design, documentation and acceptance criteria. |
FAQ: Automatic TIG Pipe Inner Wall Cladding Machine
What is this machine mainly used for?
It is mainly used for long tube inner wall anti-corrosion weld overlay, especially for hot-rolled steel pipes, seamless steel pipes, forged tubes and corrosion-resistant pipeline components.
What is the pipe diameter range?
The reference overlay processing range is from φ120mm after cladding to φ850mm. Final machine design can be reviewed according to your pipe ID, OD and required cladding thickness.
What is the maximum pipe length?
The reference maximum pipe length is up to 12,000mm. The welding gun length is listed as 12.5m in the reference data, supporting long internal cladding work.
Does the pipe need beveling for inner wall cladding?
For this reference process, the inner wall welding is described as without sloping and no bevel group pair. Final joint and cladding preparation should still be confirmed by drawing and process requirement.
What information is needed for a quotation?
Please send pipe drawing, ID/OD, length, wall thickness, pipe weight, base material, overlay alloy, required clad thickness, inspection standard and expected production capacity.
Need a Pipe Inner Wall Cladding Machine?
Send your pipe drawing, pipe ID/OD, length, wall thickness, pipe weight, base material, overlay alloy, cladding thickness and inspection requirement to HALDEN. We can help review whether an automatic TIG hot wire pipe inner wall cladding machine or another weld overlay solution is more suitable for your production.
WhatsApp: +86 18652469606
