Weld Metal Overlay

The largest global automated weld metal overlay provider

WSI’s engineered weld metal overlay (WMO) technologies provide comprehensive solutions for build-up and corrosion resistance. Our automated processes, including GMAW (Gas Metal Arc Welding) and MIG (Metal Inert Gas) welding, restore lost thickness due to wear and upgrade materials for localized corrosion issues, ensuring permanent repairs that extend asset lifespan.

We repair and upgrade a wide range of pressure vessels, including distillation units, reactors, coke drums, digesters, and high-pressure separators. Additionally, we offer structural repairs and reinforcements to mitigate stress and repair cracks, welding seams, and other mechanical damages, prolonging asset life.

WSI excels in delivering automated weld metal overlay and weld cladding solutions. Our corrosion-resistant overlays (CRO) ensure the integrity and longevity of operational assets. Through innovative weld cladding techniques and automated overlay processes, we meet the highest industry standards, providing unmatched durability and reliability for critical components.

The world leader in pressure equipment life extension

Using our patented Unifuse^® automated weld overlay technology, WSI structurally repairs, upgrades, and reinforces assets to ensure long-term, reliable performance. Constant innovation and quality improvements in Unifuse technology extend the lifetime and maximize the value of critical assets.

With an unmatched track record and extensive experience in pressure boundary restoration and preservation, WSI stands as a leader in engineered solutions and specialty welded metal overlays, delivering optimal solutions.

Innovation in automated welding technology: Optifuse – Overlay Reimagined

WSI has reimagined weld metal overlay with Optifuse, a suite of advanced technologies designed for pressure vessel owners. Optifuse boosts productivity, enhances integrity, and improves the site experience.

By focusing on continuous improvement in every weld overlay task, Optifuse reduces costs and schedules. DragonX, our automatic gouging system, minimizes prep time and delivers a smoother finish with minimal pressure boundary loss.

WSI safely enhances plant reliability by utilizing proprietary NG4 weld machines with closed-loop custom waveform technology. Optifuse extends the life of critical pressure components with higher productivity and reduced turnaround times.

Hot wire welding technology for ID nozzles

Combining hot wire technology with GTAW, WSI achieves deposition rates that are approaching those of MIG, enhancing weld quality. In hot wire welding, minimal heat input creates fusion with the base metal, while additional heat is directed onto the wire. This allows for significantly faster travel speeds than traditional GTAW, resulting in a smooth, high-quality bead.