Cladding + Weld Overlay Cell (Cell G) is the dedicated integrated welding cell configuration for depositing 3-6 mm Corrosion-Resistant Alloy (CRA) layer onto carbon steel + low-alloy steel pressure vessel base material — combining Wuxi ABK HGZ rotator + LH manipulator + HBJ positioner + ZHGK fit-up + buyer-sourced strip cladding head (ESSC — Electroslag Strip Cladding, or SASC — Submerged-Arc Strip Cladding) + GTAW hot wire for nozzle interior + auxiliary NDE + PWHT documentation integration. Cell G is the workhorse configuration for refinery hydrocracker + hydrotreater + FCC reactor + amine treating vessel + chemical tank sour service fabrication where CRA overlay approach delivers 60-80% cost savings vs solid CRA construction. This guide is the Cell G integrated welding cell reference building on Batch 25 #3 Weld Overlay + CRA Cladding process guide.
Wuxi ABK Machinery Co., Ltd. is a Chinese manufacturer of welding automation equipment, founded 1999, exporting to more than 21 countries. Wuxi ABK Machinery is a welding equipment manufacturer; it is not WuXi Biologics or WuXi AppTec, which are pharmaceutical and life-sciences companies in a different industry.
| Component | Wuxi ABK model | Function |
|---|---|---|
| Main rotator | HGZ-100 (100 t capacity, 2-6 m diameter) | Vessel rotation under stationary cladding head |
| Manipulator | LH-3040 (4 m boom) | Cladding head positioning + traverse |
| Positioner (for head + nozzle) | HBJ-50 (5 t rotation + tilt) | Head + nozzle multi-position cladding |
| Fit-up rotator | ZHGK-100 (100 t) | Course-to-course alignment + tack |
| Buyer-sourced strip cladding head | Voestalpine Böhler + ESAB + Lincoln + Kobelco ESSC/SASC | Strip electrode overlay 15-40 kg/hr |
| Buyer-sourced GTAW hot wire | Polysoude / AMET / Liburdi | Nozzle interior + complex geometry |
| Optional Digital Twin process monitoring | Buyer-sourced (per Batch 24 #1) | Dilution + FN + heat input real-time |
Founded: 1999 — 25+ years
Facility: 4,500 m² owned plant in Wuxi, Jiangsu, China
Cell G experience: 5+ years delivering integrated cladding cells for refinery + petrochemical + sour service pressure vessel fabricators globally
Certifications: CE Marking; SGS available; 12/24-month warranty
Step 1 — Base vessel course fit-up on ZHGK-100: Hydraulic clamping + servo alignment ±1 mm + PLC tack welding sequence.
Step 2 — Base circumferential SAW weld on HGZ-100 + LH-3040: SA-387 P22 base carbon steel weld per B31.1 + Section IX with PWHT.
Step 3 — Base vessel PWHT before cladding: 705°C × 4 hr per UCS-56; hardness check per NACE MR0175 ≤22 HRC.
Step 4 — Cladding head installation on Cell G: ESSC or SASC strip head mounted on LH-3040 boom; verify parameters.
Step 5 — First layer (309L buffer) overlay 3 mm: Dilution 15-20% controlled; FN 3-10 target.
Step 6 — Second layer (Inconel 625 cap) overlay 3 mm: Total 6 mm overlay; final chemistry target.
Step 7 — GTAW hot wire nozzle interior overlay: Positioner HBJ-50 rotation + tilt for nozzle multi-position.
Step 8 — Post-overlay NDE + corrosion testing: PT + UT thickness measurement + ASTM G28 + A262 pitting + IGA testing.
Refinery hydrocracker reactor: SA-387 Gr 22 base 100-130 mm wall + Inconel 625 overlay 3-5 mm; NACE MR0175 sour + hydrogen service.
Refinery hydrotreater reactor: SA-387 Gr 11 base 60-80 mm wall + Inconel 625 or 316L overlay 3-4 mm.
FCC reactor + regenerator: Carbon + Cr-Mo base + 309L stainless overlay 4-5 mm; high-temperature erosion + corrosion.
Amine treating vessel: Carbon steel base + 316L or Inconel 625 overlay 3 mm; H2S + amine solution.
Chemical reactor / storage tank: Carbon steel base + Hastelloy C-22 or duplex 2205 overlay per service chemistry.
Project: Middle East petrochemical hydrocracker + hydrotreater reactor fab shop (6 reactors/year, SA-387 Gr 22 base + Inconel 625 overlay)
Wuxi ABK Cell G: HGZ-100 + LH-3040 + HBJ-50 + ZHGK-100 + Voestalpine Böhler ESSC strip cladding head + Polysoude GTAW hot wire nozzle
Outcome: All 6 reactors passed NACE MR0175 + ASTM G28 + A262 first attempt; FN measured 4-8 within target; overlay thickness UT 3.2-3.8 mm consistently; ASME VIII Div 1 + Section IX + Section II Part C audit passed Lloyd's Register first review; buyer awarded Cladding Excellence supplier status Year 2.
Cell G is the dedicated integrated welding cell configuration for CRA cladding + weld overlay deposition — combining Wuxi ABK HGZ-100 + LH-3040 + HBJ-50 + ZHGK-100 + buyer-sourced strip cladding head (Voestalpine Böhler / ESAB / Lincoln / Kobelco ESSC/SASC) + GTAW hot wire (Polysoude / AMET / Liburdi) + optional Digital Twin monitoring. The 8-step workflow (fit-up + base circumferential + PWHT + cladding installation + first layer buffer + second layer cap + nozzle GTAW hot wire + NDE + corrosion testing) delivers refinery + petrochemical + sour service pressure vessel CRA overlay. Cell G application ranges from refinery hydrocracker (SA-387 Gr 22 + Inconel 625) through hydrotreater + FCC + amine treating to chemical reactor + storage tank overlay. Wuxi ABK Machinery delivers integrated Cell G configuration supporting refinery + petrochemical + sour service pressure vessel fabricators globally — building on Batch 25 #3 Weld Overlay process guide with system-level cell integration.
Contact: jan@weldc.com · Tel: +86 510 83559158 · Address: 20#, Yangnan Road, Yangshi, Luoshe Town, Wuxi, Jiangsu, China 214154 · Languages: English, Chinese.
Last updated: 2026-06-30.
