TECHNICAL CONSULTANCY FOR MANUFACTURING OF SPECIAL GRADE WELDING CONSUMABLES

CONSULTANT SIVAGURUNATHAN.M
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BACKGROUND INFORMATION

MR.SIVAGURUNATHAN IS QUALIFIED CHARTED ACCOUNTANT BY PROFESSION HE HAS VAST EXPERIENCE IN PROJECT STUDIES, IMPLEMENTATION&FINANCING IN 1983 , HE HAS TAKEN OVER MAILAM METALLOGEN PVT. LTD AS MD & SUCCESSFULLY REVIVED THE COMPANY. IN 1998 THE COMPANY HAS BEEN CONVERTED TO MAILAM INDIA LIMITED
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MAILAM :THE COMPANY

Ultra Modern Manufacturing Facility Product Range Includes SMAW,R&M,GMAW,FCAW,SAW Consumables Sophisticated Quality Control &Assurance Facility. Highly responsive Technical Services with All India Network Timely Delivery Internationally Recognized & Approved Brands

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SPECIAL CONSUMABLS MANUFACTURING SET-UP

HYDRAULIC POWER PACK

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PRINTING UNIT
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KNOW HOW ----SHOW HOW

WITH THE VAST TECHNICAL INPUTS AVILABLE WE CAN GIVE RECOMMENDATION FOR PROPER CORE WIRE SELECTION SUITABLE FLUX FORMULATION MANUFACTURING CYCLE OF PARTICULAR SPECIFICATION EVALUATION METHODOLOGY AS PER SPECIFICATION &ADDITIONAL TDC IDENTIFY END USER
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SCOPE

CORE WIRE SELECTION APPROACH TO FORMULATION PROCESS & PRODUCTION TECHNOLOGY EVALUTION OF CONSUMABLES MANUFACTURED TYPE APPROVAL MARKET SURVEY
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TYPES OF CONSUMABLES PROPOSED TO BE MANUFACTURED

SS E312;E308L;E309L & E904L(SFA-5.4) LAS 1CR-1/2 Mo ;2 Cr-1/2 Mo & 9Cr 1Mo(SFA-5.5) NICKEL ALLOYS E NiCrFe3;E NiCrMo3 &E NiCrFe2 (SFA-5.11) CI E NiFe-CI (Ni 55-60 %) & E NiCu-A/B(SFA5.15) Al BRONZE E CuNi & E CuAl-A2(SFA-5.6)
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CORE WIRE SELECTION

THE FACTORS TO BE CONSIDERED ARE AS INDICATED BELOW PHYSICAL CHEMISTRY

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PHYSICAL

TOLERANCE ON DIA :0.05 mm STRAIGHTNESS :0.1 mm UTS :PREFERABLY LOWER LIMIT SURFACE FINISH :DULL & ROUGH EXTENT OF EXTERNAL MARK: KNURLING MARK OF 0.1 MM &BELOW ACCECPTABLE

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CHEMISTRY (CORE WIRE)

LAS :EQMS TO IS 9Cr-1Mo 9Cr-1Mo: SS : NICKEL ALLOY : CI : Al BRONZE :

2879 EXCEPT FOR } } } SAME GRADE } }

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CHEMISTRY:LATEST TRENDS
IN VIEW OF GROWING IMPORTANCE OF CREEP & HIGH TEMPERATURE PROPERTIES COUPLED WITH LOW TEMPERATURE IMPACT PROPERTY REQUIRED ,EVEN FOR LAS HAVING ALLOY CONTENT LESS THAN 5% ALLOY CORE WIRES ARE BEING USED. WHEN ALLOYING ADDITION EXCEEDS 5%,THEY ARE CLLASIFIED AS SYNTHETIC ELECTRODES. NOT RECOMMENDED FOR CRITICAL FABRICATION DUE TO VARIATION IN ALLOY TRANSFER.
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APPROACH TO FORMULATION

ANALYSE SPECIFICATION & TDC REQUIREMENTS IDENTIFY THE CORE WIRE FLUX FORMULATION TO BE DESIGNED TO MEET TDC EVALUATE THE PERFORMANCE OF CONSUMABLES CHECK COMPLIANCE WITH SPECIFICATION & TDC
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TDC REQUIREMENTS

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CHEMISTRY: CHECK RESTRICTION ON AWS SPECIFICATION .TO SPECIFY CORE WIRE BASED ON SAME . FOR NPC INCONEL CONSUMABLES WITH CORBON OF .02 % IS SPECIFIED. THIS CALLS FOR CORE WIRE OF 0.01, LIMITS RAW MATERIAL SELECTION & HENCE INCRESE IN COST
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TDC REQUIREMENTS

PWHT TO STUDY TIME TEMPERATURE CYCLE & CHECK THE SUITABILITY FOR ACTUAL APPLICATION EVEN THOUGH CODE MAY PERMIT PARTICULAR HT CYCLE , JOB CONDITION TO BE TAKEN INTO CONSIDERATION eg:LAS HT CYCLE AS AGAINST HARDNESS
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TDC REQUIREMENTS

SPECIAL REQUIREMENTS WITH REGARD TO UTS ,IMPACT or CRACK RESISTIVITY TO BE TAKEN INTO CONSIDERATION. LEIGH CRACK RESISTANCE TEST FOR 5Cr1/2 Mo TYPE CONSUMABLES TO BE SPECIFIED. CHECK HIGH NICKEL ALLOYS FOR MICRO FISSURING
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TDC REQUIREMENTS

MECHANICAL STUDY REQUIREMENT SPECIFIED ABOVE AWS SPECIFICATION & ALSO TAKE INTO CONSIDERATION PWHT REQUIREMENTS. AWS DOES NOT CALL FOR GAURANTEED MECHANICAL PROPERTIES WITH HEAT TREATMENT FOR E 309/309Mo TYPE.
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OTHER PARAMETERS

CORE WIRE SELECTION TO SPECIFY CORE WIRE COMPOSITION TO FACILITATE SUITABLE FLUX FORMULATION PREMIXED FLUX CONSISTS OF COMBINATION OF RAW MATERIALS SUITABLE FOR SPECIFIC APPLICATION
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FLUX FORMULATION
TOBE DECIDED BASED ON CHEMISTRY AIMED & CORE WIRE SELECTED FLUX BLENDING SEQUENCE TOBE SPECIFIED DRY MIX & WET MIX SEQUENCE TOBE STATED EXPOSURE TIME FOR WET SLUGS BEFORE EXTRUSION TO BE ESTABLISHED
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TRAIL PRODUCTION
TRAIL PRODUCTION TO BE EVALUATED FOR PERFORMANCE SLAG COVER EASE OF SLAG REMOVAL WELD CONTOUR POSITIONAL CAPABILITY
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TRAIL PRODUCTION (CONTD.)

IF SATISFACTRY CHECK CHEMISTRY SUBJECT TO ACCECPTANCE OF CHEMISTRY , CARRY OUT MECHANICAL TESTS AS PER ASME IIC & TDC REQUIREMENTS EVALUATE THE PRODUCT WITH TDC & RECORD ACCEPTANCE OR RETRAIL
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PROCESS & PRODUCTION TECHNOLOGY

PRODUCTION TECHNOLOGY DRY & WET MIXING EXTRUSION PARAMETER AIR DRYING PARAMETER BAKING CYCLE PACKAGING

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PRODUCTION SEQUENCE

WIRE CUTTING CHECK LENGTH,DIAMETER,END BURR,WIRE STRIGHTNESS & SURFACE MARKS . CLEANING OF WIRE CLEAN THE CUT WIRE USING WOOD FLOUR TO REMOVE EXCESS OIL,GREASE etc
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PRODUCTION SEQUENCE

DRY &WET MIXING PREMIXED FLUX or RAW MATERIALS ADDED IN PREDETERMINED SEQUENCE TO BE DRY BLENDED FOR SPECIFIED TIME TO ACHIVE CONSISTANCY & BINDER TO BE ADDED TO GET WET MIX. MIXING TIME TO BE SPEFIED. IN CASE OF FLUX RAW MATERIALS CONTAIN COMPONENTS REACTING TO WET MIX DUE CARE TOBE TAKEN IN RAW MATERIAL ADDITION SEQUENCING
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PRODUCTION SEQUENCE

EXTRUSION PARAMETER BASED ON FLUX CONSISTANCY,THE HIGH PRESSURE EXTRUSION i.e 150 Kg/cm2 TO 300Kg/cm2 IS PREFERRED TO OBTAIN SMOOTH FLUX FINISH EXCELLENT BINDING STRENGTH AVOID COATING CRACKS CAPACITY TO WITHSTAND REPEATED BAKING CYCLE AVOID TRANSPORTATION DAMAGE
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PRODUCTION SEQUENCE
AIR DRYING
AIR DRYING TIME TO BE SPECIFIED TAKING IN TO CONSIDERATION AMOUNT OF LIQUID BINDER ADDED EXTRUSION PRESSURE HUMIDITY THE AIR DRYING TIME VARIES BETWEEN 48 Hrs. TO 96 HOURS.
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PRODUCTION SEQUENCE
BAKING THE BAKING WILL BE SPECIFIED FOR EACH SPECIFICATION .EVEN THOUGH TIME &TEMPERATURE CYCLE IS SPECIFIED ,THE TYPE OF BAKING LIKE STEP HEATING /STEP COOLING HAS REMARKABLE EFFECT ON PERFORMANCE AS WELL AS H2 LEVEL.
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BAKING OVEN

SMAW CONSUMBLE
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PACKAGING

THE FINISHED CONSUMABLES ARE PACKED AS FOLLOWS: NUMBER OF ELECTRODES PER PACKET EITHER PCS./KG BASIS COVERED IN KRAFT PAPER FILL IN POLYTHENE BAG &SEAL INSERT IN OUTER CARD BOARD BOX CARD BOARD BOX TO BE PACKED IN POLYTHENE &SHIRNK WRAPPED
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PACKAGING

PREDETERMINED NUMBER OF SUCH PACKETS IN CORRUGATED BOX COVER WITH POLYTHENE &SHRINK WRAP READY FOR DISPATCH ALLINDIVIDUAL PACKETS&OUTER CORRUGATED BOX CONTAINS BRAND NAME,AWS SPECIFICATION,,BATCH NUMBER,DATE OF MANUFACTURE ,PRODUCT DESCRIPTION & SAFETY INSTRUCTIONS . VACCUM PACKAGING CAN BE ADOPTED TO INCREASE SHELF LIFE.
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TESTING &EVALUATION

THE EXTENT OF TESTING OF CONSUMABLE OF PARTICULAR SPECIFICATION IS DEFINED BY ASME IIC &TDC ACCECPTED IN GENERAL TESTING WILL INVOLVE : CHEMICAL MECHANICAL :AWT FOR UTS,YP,%E &%RA IMPACT AT SPECIFIED 0 C FILLET TEST FOR PERFORMANCE & POSITIONAL CAPABILITY
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TESTING EVALUATION
OTHER TESTS ASPER TDC SUCH AS HARDNESS RESTRICTION FERRITE CONTROL CRACK DETECTION TEST HIGHER IMPCT REQUIREMENTS H2 LEVEL CONTROL REQUIRED VALUES ARE COMPARED TO OBTAINED VALUES & ACCECPTABILITY OF CONSUMABLE IS DETERMINED.ANY DEVIATION CALLS FOR RETEST OF MINIMUM TWO SAMPLES.

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TYPE APPROVAL WITH END USER IN STRATEGIC/HIGH TECH SECTOR

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TYPE APPROVAL

CONSUMABLES FOR CRITICAL APPLICATION-HENCE CONSUMER DEMANDS DATA BASE. CONSISTANT INHOUSE RESULTS & RESULTS FROM THIRD PARTY LABORATORIES WILL HELP IN READY ACCECPTANCE OF PRODUCTS FOR EVALUTION
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TYPE APPROVAL(CONTD)

PRODUCTS WITH WELDER APPEAL WILL PROPEL THE ORGANISATIONS TO EXPEDITE TESTING & EVALUTION. SUBJECT TO TDC BEING MET ,THE EASE OF HANDLING THE PRODUCT i.e USABILITY WILL DECIDE THE PROCUREMENT DECISION.
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MARKET DEVELOPMENT
MARKET DEVELOPMENT INVOLVES CLASIFICATION OF INDUSTRY BASED ON PRODUCT NEEDS IDENTIFY AVAILABILITY OF SUITALE PRODUCT IN PRODUCTION RANGE SUBMIT SAMPLE & FOLLOWUP FOR APPROVAL AFTE INITIAL APPROVAL BAIN TRAIL ORDER & OBTAIN SHOP APPROVAL GET INTO RATE CONTRACT FOR SUPPLIES
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MARKET SURVEY
CONDUCTING OF MARKET SURVEY FOR SPECIFIED CONSUMABLES WILL BASICALLY INVOLVE IDENTIFYING OF THE EXSISTING USERS SHORT LIST THE NEW PROJECTS EXPECTED TO NEED SUCH CONSUMABLES IMPORT SUBSTITUTION DEVELOP EXPORT MARKET

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WE CAN..

DEVELOP FORMULATION OF THE PRODUCT PROVIDE GUIDE LINES FOR SELECION OF APPROPRIATE WIRE &FLUX COMBINATION GUIDE IN APPLICATION OF THE PRODUCT &EVALUATION OF THE SAME RECOMMEND STEPS TO BE TAKEN FOR QUALIFICATION OF PRODUCT TO AWS SPECIFICATION.
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WE CAN

PROVIDE GUIDANCE FOR QUALIFICATION OF PRODUCT FOR THIRD PARTY APPROVAL PROVIDE GUIDANCE FOR MARKET DEVELOPMENT DESIGN FORMATS &DEVICE SYSTEM TO ENSURE TRACEABILITY OF THE PRODUCT GUIDE IMPLEMENTATION OF SYSTEM & PROCEDURE TO GET ISO ACCREDITION.
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THANK YOU
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