MANUFACTURE OF WELDING CONSUMABLES & FLUXES ByR.D.

Pennathur of MAILAM INDIA LTD ,PONDICHERRY INTRODUCTION:

Welding /Metal Joining is a process of joining of one or more metal of similar type or different type so as to achieve in the weld joint at least minimum property of one of the material being joined. The American Welding Society has defined the Weldability in a simple way as follows Weldability is the capacity of a metal to be welded under the fabrication conditions imposed! into a specific! suitably designed structure! " perform satisfactorily in the intended service. #or this purpose we need heat source " consumable to add as filler metal. $ased on the system adopted to provide the same! there are different processes available. The most commonly used processes are as follows SMAW %TAW %MAW SAW #&AW We will study the various manufacturing processes! brief application details. The manufacturing of consumables for above application consists of following steps 'reparation of wire 'reparation of flu( )et us see the manufacturing process of SMAW &onsumable. The se*uence of operation includes Wire +rawing Wire &utting to re*uired Si,e Wire &leaning #lu( mi(ing - +ry " Wet Slug preparation .(trusion Air +rying $a/ing 'ac/ing #or %TAW! the se*uence involves only preparation of Wire as #lu( is normally not involved. #or shielding purpose Active or 0nert gas is used. The 'roduction Se*uence involves Wire drawing to re*uired Si,e 'ic/ling Water washing 'hosphating &opper coating &ut to 1e*uired length Stamp the AWS Specification 2

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#or %MAW the se*uence is very similar to %TAW Wire but wire is in continuous form " spooled for easy handling. #or SAW the wire " flu( are separately manufactured. The weld metal will be result of Wire3#lu( combination being used. The #&AW consumables are commonly /nown as 40nside -5ut4 as the metal is outside and flu( is inside as against SMAW consumable where in core wire is inside " flu( is outside. The introduction of #&AW process has caused revolution in the industry! as the product is capable of easy handling! positional welding suitability! and availability in wide range of alloying specification " higher productivity. .ven though the unit cost of #&AW consumables appears higher than SMAW consumables ta/ing normal overhead of organi,ation into consideration! the #&AW consumables becomes more economical per /g of weld deposited! 0n short the development of various welding process was driven by need for good welds! improved productivity " welders comfort. All the process ma/es use of core wire for weld deposition " flu( / gas or both for weld protection. The following table highlights the role of wire " protective flu( /gas.

PROCESS WIRE FLUX DESCRIPTION

PROCESS SMAW GTAW GMAW SAW FCAW

FILLER &51. &ut length 5n spool 5n spool 5ut side

FLUX/GAS 5n Surface .(ternal gas Argon .(ternal gas &o6 Separate flu( #eeding &ore

TYPE #lu( coated %as shielded %as shielded Wire 7 #lu( #lu( 7 %as +ual Shield

As can be seen in each of the process! the main components are core wire to AWS Specification for weld deposition " suitable flu( or gas for shielding of weld metal. The most commonly used process in 0ndia still continues to be SMAW due to easy availability of consumable to re*uired specification " availability of s/illed man power. .ven though %MAW proved to be more productive process! the inherent problem of limited specification wires available has restricted the 0ndustrial Application. SAW even though most productive process with wide spectrum of specification available as wire 7 flu( combination is *uite popular for )3Seam " &3Seam application. The limitation of process in its unsuitability for positional application. #&AW consumable has ta/en the most sought alter position as process is capable of 8igher 'roductivity. &apability for positional application coupled with easy availability in various specification.

SELECTI ON CRITERIA

Chemical & Mechanical Properties Commercial Availability of Pro !ct S!itability for Restraint "el s #$y ro%en Level in "el Metal Type of &as Shiel in% to be !se 'easibility of Application Cost Factor

ESTIMATION OF WELD METAL COST MAT.10A) .).&T15+. 9

S80.)+0:%

WELD METAL COSTING

I!ED COST J50:T '1.'A1AT05: #0;T<10:% TA&=0:% RS '1.8.AT0:% &).A:0:% 0:S'.&T05:

VARIABLE COST '5W.1 ".><0'M.:T .).&T15+. &5ST LABOUR &OVERHEAD That is to say HIGHER THE PRODUCTIVITY LOWER IS THE PRODUCTION COST H !" #$%&!' &!#( "(!)&* +$#&(! ,(- "(!*&#&(! . /()# )0&#$-1 P+(*0"#&2 P+(" )) ! *) #( - ) 1 "# * #( $"3& 2 G((* & E"(!(/&"$1 WELDMENT4 63?@ A32?@ 80-85%

D $+ D+4 B$1$)0-+$/$!&$/ . D 5#4 (6 P+(*0"#&(! E!''4 P1 $) 6&!* $-(2 -+& 6 7+&# 05 (! M$!06$"#0+&!' (6 W 1*&!' C(!)0/$-1 ) &6108 )4 I 7&11 + $"3 9(0+ * 5$+#/ !# -9 :-;0 AM (! 5#3 <0! 4 B )# W&)3 ). R4D4P !!$#30+