What exactly is unsatisfactory about the appearence?

I hate to break it to you pal, but it's not GTAW process...

Here's the process... It's CMT which means Cold Metal Transfer, and it's a relatively new method of GMAW metal transfer developed by Fronius GmbH.

How do I know this for a fact? Well, let's just say that I find things and I found this which comes from the company that the OP mentioned in his second post:

"Weld metal overlay (cladding) High weld metal overlay quality with 10 UHLIG features:

    1) Use of 4-component inert gas He 30s - specially developed for UHLIG weld metal overlay

    2) Use of innovative CMT* welding technology (*Cold-Metal-Transfer) C/o Fronius

    3) Two parallel welding burners per rig

    4) Vertical-down welding position

    5) Double-layered weld metal overlaying

    6) Intelligent strengthening layer structure in the particularly corrosion-prone fin area

    7) Double blasting prior to weld metal overlaying

    8) Shrinkage taken into account

    9) Glass granulate blasting of the weld metal overlay surface

  10) Circulated water cooling

Results: Minimal Fe content and uniform overlay weld thickness.

In fact, here's the link to "Uhlig's" site:

http://www.uhlig.eu/schweissplattieren.asp

Look @ page two because that's where the above mentioned information comes from.

This is Fronius's Cold Metal Transfer process:

http://www.fronius.com/cps/rde/xchg/fronius_international/hs.xsl/79_9399_ENG_HTML.htm

Take a look at the video's in the web page and you'll see that CMT is similar to short circuit transfer except for one big difference... The control of wire movement as the short circuit occurs is what makes it different, and if you read the article explaining the process, you'll understand better how this method of transfer really works...

This page explains it better than I could, so I'll defer to Fronius instead.

http://www.gxcme.edu.cn/jpkc1/hj060522/weld12.6/lesson/lesson5/5_1_6.pdf

A good friend of mine named Stephan Engelhard who works for Fronius and used to frequently contribute here but, is currently workign on securing his Masters Degree in - oh I forgot whether it's Welding Engineering or material sciences with an emphasis on Welding Engineering, explained it all to me a few years ago when they (Fronius) first introduced the method of transfer process for commercial use... With this process, one can even join steel sheet to Aluminum sheet as well which is simply amazing to watch for an "old geaser" like myself.

Judging from some of the pics below, I do indeed see a slight bit of spatter yet, it's an amazingly huge improvement in cosmetically sound weld overlaying when compared to what is shown in the first picture from the Original Poster (OP), Barbaros.

Anywho, it's definitely NOT GTAW. So enjoy the read and for Barbaros, I would suggest you contact Fronius USA to look further into this process or if it's more economically efficient, get in touch with UHlig Wel-Cor GmbH, or WSI/Aquilex's "Unifuse" weld overlay services... Here are their links:

http://www.uhlig.eu/index.asp?slcSprache=en&FID=&class=

http://www.aquilex.com/pdf/unifuse-tube.pdf

Well, that's it for me now... Btw, these pics are from Uhlig's website...I hope this clarifies any confusion and helps whoever needs it.

Respectfully,
Henry

Please read the Original Poster's (OP) description of the second weld overlay picture which is a sample either given or shown to Barbaros by "UHLIG WEL-CO."

Then go down to the link I posted in my last post from UHLIG... It clearly shows that it's the CMT process of GMAW as written in the link on page 2... So, if you only read page 1, then you probably missed reading the description of the process specification UHLIG has on page two previously...

There's no GTAW "dry wash" done after the CMT layer is deposited although, I have also seen it done in the field first hand, and this process developed by both UHLIG and Fronius eliminates the need for a GTAW "dry wash which in itself is a significant savings in the costs to deposit the weld overlays.

Finally, CMT is a different animal when compared to traditional short circuit transfer of GMAW, and if you read the explanation of how it works in the .pdf's below, you'll understand what I'm talking about, and therefore comprehend why a GTAW "dry wash" is not required to achieve the weld profile, dlution, deposition pattern in order to meet the inspection requirements that are also shown in one or two of the pics in my previous post.

http://www.gxcme.edu.cn/jpkc1/hj060522/weld12.6/lesson/lesson5/5_1_6.pdf

http://www.digitalweldingsolutions.com/CMT.pdf

You are correct in noticing that they are shop weld overlays, and I too would like to know if they (UHLIG or anyone else for that matter) use a similar process (CMT) in the field for repairs in existing boilers.

Respectfully,
Henry

Fronius is not just the best power supply in Germany... Nobody in the world can do what they do.

Ed, is very critical of Pulsed appilcations when they are not necessary...  But There are many applications where specitaly equipment can do a much better job... When things like dilution are an issue, traditional spray transfer is never going to produce like GMAWP or RMD, STT, or CMT,.

So what if a Fronius costs twice as much as the next machine?

One scrapped job in your business or a couple dozen hours of rework pay for a top of the line power supply.

I'm pretty sure you could get a Fronius rep to come in for free, and demo his equipment so you can see for yourself the results and compare them to typical equipment.

Getting nickel alloys to run vertical down with traditional spray transfer is always going to be problematic.