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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 thematerial being joined.

The American Welding Society has defined the Weldability in a simple way as followsWeldability is the capacity of a metal to be welded under the fabrication conditionsimposed! 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 thesystem 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

$aing

'acing

#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*uenceinvolves

Wire drawing to re*uired Si,e

'icling

Water washing

'hosphating

&opper coating

&ut to 1e*uired length

Stamp the AWS Specification

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'ac

#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 ofWire3#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( isoutside.

The introduction of #&AW process has caused revolution in the industry! as the productis 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 taing 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 maes use of core wire for

weld deposition " flu( / gas or both for weld protection. The following table highlightsthe role of wire " protective flu( /gas.

PROCESS WIRE FLUX DESCRIPTION

PROCESS FILLER FLUX/GAS TYPE

SMAW &51 5n Surface #lu( coated

GTAW &ut length(ternal gas

Argon%as shielded

GMAW 5n spool(ternal gas

&o6%as shielded

SAW 5n spoolSeparate flu(

#eedingWire 7 #lu(

FCAW 5ut side &ore#lu( 7 %as

+ual Shield

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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 silled 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 taen the most sought alter position as process is capable of8igher 'roductivity. &apability for positional application coupled with easy availability

in various specification.

SELECTION CRITERIA

Chemical & Mechanical Properties

Commercial Availability of Pro!ct

S!itability for Restraint "els #$yro%enLevel in "el Metal

Type of as Shielin% to be !se

'easibility of Application

Cost Factor

ESTIMATION OF WELD METAL COST

MAT10A)

)&T15+

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S80)+0:%

WELD METAL COSTING

I!ED COSTJ50:T '1'A1AT05: '18AT0:%

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