PROJECT

REPORT FOR
WELDING
ELECTRODES

2/635, Arasamara Thottam, Venkitapuram,chinniyampalayam,

Coimbatore-641 062.
Phone : +91 422 – 2934784, Mobile: +91 98430 41421
E-mail: admin@logosweld.com / sales@logosweld.com
Website: www.logosweld.com
1. INTRODUCTION
Welding plays an important role in the gross national product of any industrial economy.
Even in very advanced countries like Us statistics say that half the gross national product
has association in one way or the other with welding. In a country like India, African
Countries, Arab Countries, where rate of growth of industrial sector has to be accelerated
in order to meet the needs and aspirations of the people, the importance welding plays
cannot be over emphasized. Welding is one of the means by which growth can be
achieved in fields as diverse as power and fertilizers, industrial machinery, earth moving
equipment, water and gas pipe lines and on thermal, nuclear and hydro-electric power
generation.

Rapid strides have been made in welding technology and the present trend in advanced
countries is to switch over from manual arc welding to automatic and semi-automatic
methods. The percentage of metal deposited by automatic and semi-automatic methods is
49% in the US, 50% in Western Europe, 48% in Japan and 25% in Russia. An estimate of
the figure for India, African Countries, Arab Countries puts it at not more than 4% with
the balance 96% being deposited by manual welding.
The main reason for this lay in the ease of application and that stick electrode embody in
compact from all the material required for welding. Unlike the automatic/semi-automatic
processes, manual arc welding requires a simple power source only. Also, decades of
development have led to the availability of a comprehensive selection of electrodes for
various types of applications.

We are happy to provide this useful project for the benefit of prospective entrepreneurs
planning to set up manual arc welding electrode manufacturing industry.

2. PRODUCTION PROCESS
2.1. The process of production of manual arc welding electrodes fall into two main
sectors, viz.,
- Preparation of core wire and flux
- Extrusion (coating), baking and packing

2.2. PREPARATION OF CORE WIRE

Electrode quality wire confirming SAE1006/1008 with low carbon and low silicon is
available at open market. The wire rod coils are converted to the drawn wire coils of sizes
such as 2.5 mm, 3.15 mm, 4 mm etc. at the wire drawing plants . It is then cut and
straightened in a "STRAIGHTENED AND CUTTING MACHINE".

Cont…….
2.3. PREPARATION OF DRY MIX
Rutile, low carbon ferro manganese, cellulose, titanium di-oxide, mica, feldspar, quartz,
etc. are some of the chemical powders used as the raw materials for the preparation of
flux. These chemicals are available indigenously and they are weighed accurately as per
the technology for each type of electrodes and they are mixed in a DRY MIXER to set a
homogeneous mix.

2.4. PREPARATION OF WET MIX AND BRIQUETTING

Potassium silicate is used as the binding agent. The flux is mixed with silicate in a correct
proportion to obtain a wet mix in a WET MIXER . The wet mix is then pressed to form
briquettes in a hydraulically operated press in order to load the flux in the flux cylinder of
the extruder.

2.5. APPLICATION OF THE COATING BY EXTRUSION

The coating of flux is conducted by extrusion press in which the flux briquettes are fed
through a cylinder under pressure. While the wire is fed into the wire magazine of the
electrode press the briquettes are introduced into the extrusion cylinder of the press.
During operation the core wire is fed one by one and coated with the flux by way of
nozzle system in the die box incorporated in the extrusion press. The electrodes coming
out from the press are tested in an eccentricity tester. The rejected electrodes are taken
into the flux stripping machine where the flux are stripped off and the core wire and flux
can be reused.

The electrode coming out from the press is to pass through a conveyor to the brushing
machine for brushing of holding end and cleaning the same on tip side for easy striking of
the electrode. After that the electrodes are put in the frames for air drying and after
certain period they are fed into the oven. The whole process required an EXTRUDER,
WIRE FEEDER, CONVEYOR, PRINTING UNIT and BAKING OVEN.

2.6. DRYING OF COATED ELECTRODE

After air drying of the coated electrode they are baked 1 to 2 hours at up to a temperature
of 1500 C depending on the type of coating to remove excess moisture as this may impair
the stability of the arc. The moisture content in the electrode should not exceed 4%.

2.7. QUALITY CONTROL

Quality control in electrode making shop calls for, constant checking on the PSD of the
ground ingredients, their proportioning and mixing, application procedures, moisture
content and drying conditions. In addition, the chemical analysis of the core wire is
determined, the coating thickness is measured and the electrodes are tested on trial plates.

Cont……..
 2.8. GRADING AND PACKING
The finished electrodes are stored and wrapped in polythene or waxed paper and packed
in cartons. Cartons are packed in wooden cases or in master cartons. Number of
electrodes in each carton varies from 50 to 100 pieces. A case will contain approximately
12 to 16 cartons. Electrodes are issued with certificate stating the classification, type and
size, name of manufacturer, batch number, core wire grades, date of manufacture and test
result.

2.9. PLANT AND MACHINERIES

The various equipments and machineries to suit different plant capacities, on turnkey
basis are available from Logos Weld Products, Coimbatore,India.

2.10. TECHNICAL KNOW-HOW

Technical know-how for production of manual metal are welding electrodes of general
purpose grade as per AWS E6013 is available from Logos Weld Products, Coimbatore,
India.

3. LAND BUILDING
The total built up area required

for 10 T plant is 12,000/ Sft for welding electrode plant and wire drawing.

Building of construction with normal industrial flooring and asbestos northlite roofing
would be adequate. Land requirement can be planned based on availability and price
keeping in mind future expansion.

4. POWER
The requirement of electricity would be:

for 10 T plant is 275 HP for welding electrode plant and 150HP for wire drawing unit

5. RAW MATERIALS AND THEIR AVAILABILITY

The main raw materials required for the project are rimming quality steel, rutile and other
chemicals such as ferro manganese, silicate, china clay, mica, cellulose, titanium di oxide
etc. They are available freely in the market and also from us as stated below.

Cont……
5.1. STEEL
Steel is available in the open market such as in India and also available in South Africa,
Srilanka, Turkey, Indonesia & China.

5.2. RUTILE
Indigenous Rutile is available at India and also available in South Africa, Srilanka,
Australia, Taiwan, Indonesia.

5.3 OTHER CHEMICALS FOR M.S. ELECTRODES

Other chemicals such as ferro manganese, calcite, china clay, mica, cellulose etc.
are freely available at the global market and also from us.

6. WATER
The production process would need small quantities of water, say about 250 liters per
day. Total requirement including those for amenities would be around 600 liters per day.

7.EFFECT ON ENVIRONMENT
There is no by products in the process of welding electrode manufacturing. However the
improperly coated electrodes are collected from the conveyor and with the help of the de-
fluxing machines, the flux from the wire is removed. Then the wire and flux are re-used.
Hence there is no impact on the environment-which makes an electrode plant Eco-
friendly.

LIST OF MACHINERY FOR 2 TON PLANT

 Wire Straightening and Cutting Machine
 Dry Mixer
 Wet Mixer
 Slug Press
 Extruder
 Wire Feeder
 Conveyor
 Oven
 Shrink Wrapping Machine
 De-fluxing Machine

Supplier:
All the above machines are supplied by LOGOS WELD PRODUCTS, Coimbatore, India.
 SCHEMATIC DIAGRAM OF ELECTRODE PRODUCTION

Raw Wire Coil Binders Raw Materials (Minerals)

Materials

Preparation of Wire Cutting Dosing Dry Flux Preparation

Flux

Wet Flux
Preparation

Production Loading wire Briquetting

in the Hopper

Extrusion of
electrodes

Printing

Rejection Concentricity testing and

visual inspection

Baking

Rejection Visual inspection

Recovery

Packing Storing

www.logosweld.com
 How we can guide on this project?
1. Machinery
2. Additional machineries
3. Flux or coating component
4. Packing materials
5. Wire rods
6. Quality & Technical
7. Market
8. Labors
- Supplied by LOGOS WELD PRODUCTS.
- Supplied by LOGOS WELD PRODUCTS.
- a) If you required you can purchase from us
(or)
b) If you need we will give you technical know
how of flux and you can buy raw materials
from us.
(or)
c) Get only technical know how and buy raw
materials from near source.
- As per our instruction you can arrange the local
source.
- You can purchase from local market or import
wires from Turkey, Indonesia, South Africa.
- a)As per your requirement we can give you a good
technical know how along with machinery for
E6013 & E7018.
b)Other electrodes like E6010, E7016, SS,
Hardfacing, CI, cutting and gouching you have
buy the Know how (formula) from us.
- You have to generate the orders and we will guide
in the procedures.
- a)If you required we will send an operator.(or)
b)We will train your person how to operate the
machines.

For further information please contact.

2/635, Arasamara Thottam, Venkitapuram,chinniyampalayam,

Coimbatore-641 062.
Phone : +91 422 – 2934784, Mobile: +91 98430 41421.
E-mail: admin@logosweld.com / sales@logosweld.com
Website: www.logosweld.com