TwinWire
RapidClad 2.0

Weld overlay cladding fuses a layer of corrosion-resistant or wear-resistant alloy onto the surface of a cheaper base metal. It gives carbon-steel components — pipes, valves, flanges, vessels — the surface performance of an expensive alloy at a fraction of the solid-alloy cost. TIP TIG RapidClad typically applies ERNiCrMo-3 (Alloy 625) for corrosion protection, hard-facing, and surface repair.

The TwinWire RapidClad 2.0 reaches up to 20 lbs/hr (9.1 kg/hr) — the highest deposition rate available for TIG overlay cladding. Two wires are fed simultaneously, and dynamic wire feed holds optimal temperature and dilution control at every speed.

Dilution is how much base metal mixes into the overlay. Too much dilution pulls iron up into the cladding and weakens its corrosion resistance — often forcing a second layer to meet the required chemistry. RapidClad cuts dilution by around 80 %, so the overlay keeps its intended chemistry and frequently meets spec in a single layer, saving time and filler.

The most common is Alloy 625 (ERNiCrMo-3) for corrosion protection, but the process also applies other nickel-based corrosion-resistant alloys, hard-facing alloys for wear resistance, and repair overlays. The controlled heat and low dilution preserve the deposited alloy's integrity.

Anything exposed to corrosion or wear in service: pipelines, valves, flanges, pressure vessels, valve and pump components, and CRA pipes and elbows. Cladding protects these critical parts long-term while keeping the structural body in lower-cost carbon or low-alloy steel.

It is TIP TIG's dedicated cladding system. "TwinWire" refers to feeding two filler wires at once for maximum deposition, while the RapidClad 2.0 control keeps heat input and dilution low at high travel speeds — the combination that delivers top deposition rates with the lowest dilution on the market.