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
'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 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 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 spool
Separate flu(
#eeding
Wire 7 #lu(
FCAW 5ut side &ore
#lu( 7 %as
+ual Shield
6
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 CRI TERI A
Chemical & Mechanical Properties
Commercial Availability of Pro!ct
S!itability for Restraint "els #$yro%en
Level in "el Metal
Type of &as Shielin% 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: '1.8.AT0:%
#0;T<10:% RS &).A:0:%
TA&=0:% 0:S'.&T05:
VARIABLE COST
'5W.1 ".><0'M.:T 63?@
.).&T15+. &5ST A32?@
LABOUR &OVERHEAD 80-85%
That is to say
HIGHER THE PRODUCTIVITY LOWER IS THE PRODUCTION COST
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!*) #( - )1"#* #( $"3&2 G((* & E"(!(/&"$1 WELDMENT4
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