Welding Services

Process Overview – Welding is a process of joining metals or thermoplastics by using a high amount of heat generated by a power source. This melts the material to fuse together and form a metallurgical bond which is protected by a shielding inert gas to prevent contamination and oxidation. Few commonly known welding services offered by us include GMAW (Gas Metal Arc Welding), GTAW (Gas Tungsten Arc Welding), SMAW (Shielded Metal Arc Welding), FCAW (Flux Cored Arc Welding) and Laser Welding. While this technology has long been used for joining metals, we also utilize it for overlaying specific alloys on carbon steel and stainless-steel substrate to impart enhanced properties. Our main expertise in this area include : GTAW – It utilizes a non-consumable tungsten electrode to produce the weld when a filler wire is introduced in the arc protected by a shielding gas. It produces a homogeneous and low dilution metallurgical bond with the base metal substrate and mainly used for deposition of Stainless Steel and its alloys, Nickel, and its variants, Stellite and its variants. Weld overlay followed by PWHT (Post Weld Heat Treatment) makes the welding denser and removes any residual stresses induced by the welding. PTA – Plasma Transferred Arc is a process used to fuse a metallic coating to a substrate to improve its resistance against wear and/or corrosion. Metal powder is fed into a molten weld puddle (fusion bath) generated by the plasma arc at high temperature (up to 20,000 °C). Deposit thickness can range from 0.6 to 6.0 mm, width from 3 to 10 mm when using a single pass; multi pass welding reaches deposit thickness up 20 mm and width over 30 mm. The deposit microstructure is dense with formation of dendrites during solidification. One of the most important features of the PTA process is the control of dilution which is as low as 5%. It is usually preferred for overlaying of exotic materials such as Nickel and its variants and Stellite and its variants. Spray and Fuse - It is an extension of coatings done by Powder Flame Spray process wherein the sprayed coating is fused with the base material by application of external heat energy using Oxy-Acetylene torch, Induction coil, Furnace, Laser beam or an external heating source. The coating is taken to solidus temperature (1020 to 1100°C) at which the coating fuses and voids and porosity in the coating collapses making the coating denser and more homogeneous. This also forms a fine metallurgical bond with the prepared substrate which makes the coating capable of enduring impacts. A variety of materials can be deposited by this process to achieve properties required for different critical applications such as Cobalt and its variants, Nickel and its variants, Carbide and its variants etc. Laser Cladding - It is the use of electrically produced laser light to heat wire or powder material and apply it to a substrate surface. Since the heat input generated by laser is less it produces minimal HAZ (Heat Affected Zone) which is detrimental to the weld quality. Laser cladding is often performed by robotic manipulators and produces a very dense and homogeneous deposit with the least amount of dilution. Vacuum Brazing – It is a process of joining two similar or dissimilar metals by heating a braze alloy between the components inside a vacuum furnace. The braze alloy has a lower melting temperature than the parent component and melts easily to fill the clearance and form a joint. Vacuum Brazing is preferred where leak tight joints are required mainly in critical Aerospace and Defence components, Automotive and HVAC industries. We specialize in vacuum brazing of nickel and aluminium based filler metals which are available in the form of paste, wire, and foil.   Capabilities Latest weld overlay and laser cladding technology Weld overlay facility integrated with heavy engineering tool room Welding and Cladding processes available – GTAW, PTAW, SMAW, FCAW and Laser. Welding and Laser cladding of exotic materials such as Nickel and its variants, Cobalt and its variants, Carbide and its variants etc. Completely automated welding setup capable of welding parts up to 2000mm Dia and 2000mm long Pre and post machining of weld overlayed parts up to 1500mm Dia and 6000mm long Grinding of weld overlayed parts up to 800mm Dia and 6000mm long Heat treatment furnaces for pre and post coated/welded parts up to 2000mm Dia and 8000mm long Complete end to end manufacturing of weld overlayed/cladded parts and assemblies Dedicated welding setup for batch and production parts Qualified welding operators capable of manual as well as semi-automatic welding Availability of WPS, PQR and WPQ for range of materials qualified by internationally recognized certifying bodies NADCAP certified High Vacuum Brazing furnaces for Aerospace and Automotive parts In-house laboratory for microstructure analysis of welded samples including micro-hardness and bond strength evaluation Welding facility certified to AS 9100 Rev.D and ISO 9001 Quality Management System Welding shop approved by BHEL and MNC’s such as Siemens and L&T   Application and Benefits Like plating and coatings, weld overlay finds applications in critical working environments such as Oil & Gas, Steel, Pumps and Valves, Hydraulic, Plastic Extrusion etc. Few commonly welded overlaid parts include valve spindles, diffusers, shafts, pump casings and rings, mandrels and housings, piston rods etc. Weld overlay and Laser cladding offer numerous advantages such as : Wide range of exotic materials can be used in different forms Flexibility to apply on any base material substrate Forms a metallurgical bond which gives high impact strength Enhances wear, abrasion, corrosion, and high temperature oxidation resistance Improves operational life of part Reduces downtime and breakdown costs  

Spot Welding Services provide efficient and reliable metal joining solutions for various industries, including automotive, electronics, and appliance manufacturing. Using resistance spot welding, these services focus on joining overlapping metal sheets by applying pressure and electrical current to create strong, localized welds. Ideal for high-volume production, spot welding offers advantages such as rapid processing, minimal material distortion, and consistent weld quality. These services are perfect for assembling components like car bodies, metal enclosures, and structural frames. Spot welding services ensure durable, precise, and cost-effective connections, enhancing overall manufacturing efficiency and product performance in demanding industrial applications.

We provide welding of excavator buckets. Life of excavator buckets can be extended by providing a ling of wear resistant manganese steel strips. We also carry out repairs to damaged buckets used for soil excavation and rock cutting. Welding is done using co2 welding machine which gives good bond between parent material and new material.

AYYAPPA GEOSYNTHETICS INSTALLERS  capable of managing all fabrication for HDPE and PP pipe solution including the design, engineering certification, fabrication, construction, installation and commissioning.We fabricate from install HDPE liners, and complete minor civil works. Works range from emergency repairs, shutdowns, and maintenance upgrades through to complete HDPE piping systems installations.All welding for HDPE piping systems is performed in accordance with thoroughly developed quality standards, with all weld parameters calculated and recorded on weld logs and all worked performed in safety management system.We use state of the art welding equipment which reduces manpower requirements on site and improves productivity.AGI also carries a large range of pipe and fittings, including stubs, backing rings, reducers, bends, tee pieces, valves, gaskets and bolts – all available off the shelf – in sizes from 32mm to 630mm. This enables us to deal with our customers emergency needs promptly, avoiding costly delays.Applications Welding of HDPE Pipes. Floatation, Shifting and Sinking of Pipe Lines. Installation of Pipe Line on Sea Bed. Head works and generator installations Complete pipeline welding and installation Valve installations Testing and commissioning Operate and maintenance The Ranges of Varied Dimensions of Hdpe Welding Machines are Like 63-160 mm 90-315 mm 315-630 mm

SSV Vessels fabrication division handles a wide range of custom fabrication projects including conveyors, Hoppers, Manifolds, Skids and other complex equipments that are specific to your application. Our skilled & experienced team uses the latest in welding and fabrication technology to bring you perfect pieces every time.   Structural Fabrication SSV Vessels handles the building of all structural steel projects. All of our structural products are designed with safety in mind and rated to meet your load and weight requirements.   Heavy Fabrication SSV is capable of large scale custom metal fabrication projects of any size including industrial structure, large capacity water storage tanks and more.   Finishing Whether its Blasting, Painting or Powder Coating you want, SSV Vessels Private Limited has all the technological know-how to satisfactorily provide cost effective and durable solutions to provide surface protection solution to our clients.

Our Robotic CO2 Welding Service offers cutting-edge automation for precise, efficient, and cost-effective welding solutions.   Utilizing state-of-the-art robotic systems, we ensure high-quality welds across diverse materials and configurations. Our skilled technicians guarantee adherence to industry standards, emphasizing safety and flexibility. From customized projects to large-scale production, we provide fast, reliable, and environmentally conscious robotic CO2 welding services, optimizing productivity and minimizing costs for our valued clients.

This course is mainly for personnel in Production, QA, Maintenance and purchase functions. Minimum qualification Science graduate/ Diploma/ Degree in Engineering.The course covers various welding techniques in brief and more in detail on Metallurgy at Weld joint. How the heating and cooling of material at weld joint behave, What property changes occur and how to control metallurgical properties of weld joint are discussed.Next step Register for the course by filling up following details. (as per attachment). Attend course and get certificate Course Fee Per person₹3000 / US $ 40

Our Welding Fixtures Designing Service provides tailored solutions to enhance precision, efficiency, and quality in welding operations. We specialize in designing robust and reliable fixtures that ensure proper alignment, secure holding, and repeatable accuracy for various welding applications. With a team of skilled professionals and cutting-edge design tools, we create fixtures that meet industry standards and optimize production workflows. Whether for automotive, industrial, or custom requirements, our designs prioritize durability, ease of use, and cost-effectiveness. Partner with us for innovative welding fixture solutions that boost productivity, reduce downtime, and ensure superior results in your manufacturing processes.