MAILAM INDIA LIMITED

PONDICHERRY
FCAW MODERN TOOL FOR COST CONTROL ???
The present emphasis in Fabrication Indstr! is on "rodcti#it! $ %a&it!
at most economica& cost' The process re&iabi&it! in combination (ith eas!
a#ai&abi&it! o) re*ired )aci&it! p&a!s a #er! important ro&e in se&ection o)
process 'The &ibera&i+ation o) econom! has ensred that (ho&e (or&d has
become a ,&oba& -i&&a.e' Ths no Indstr! is ins&ated )rom ,&oba& Trends
$ it is essentia& to /eep pdatin. techno&o.! to meet Internationa&
Standards' 0ence need )or adoptin. (e&din. techni*es1 (hich (i&& .i#e
hi.her prodcti#it! $ sti&& meet strin.ent %a&it! re*irements' FCAW has
emer.ed as c&ear (inner nder this scenario'
2'3 INTROD4CTION5
Industrialization & Globalization has mad !abri"ation Industr# hi$hl#
"om%titi& businss' Th !abri"ation n$inr has mu"h (idr "hoi" in
sl"tion o! %ro"ss in &i( o! im%ro&mnt in a&ailabilit# o! E)ui%mnts
as (ll as "onsumabls' Ho(&r a"h %ro"ss has its o(n ad&anta$s &
limitations' Th "ontinuous u%$radin$ o! Matrials as (ll as "riti"al
dsi$n %aramtr *%s +ldin$ En$inr to d&lo% n(r o!
"onsumabls to suit ,abri"ation r)uirmnts' Thus ,abri"ation En$inrs
ado%ts Pro"ss & Consumabl- (hi"h "an $i& hi$hr Produ"ti&it# &
Consistnt .ualit#' In this "ont/t ,CA+ has im%ortant rol to %la#'
6'3 CRITERIA FOR SELECTION5
,or a $i&n s%"i!i" a%%li"ation- th Consumabl sl"tion (ith "om%atibl
Pro"ss is to b don ta*in$ !ollo(in$ !a"tors into "onsidration'
Mtallur$i"al
M"hani"al
Pro"ss
0
6'2 METALL4R,ICAL
,a"tors to b "onsidrd ar-
0' 1as Matrials
0' M"hani"al Pro%rtis
2' Chmi"al "om%osition
3' Corrosion r)uirmnts
4' Ph#si"al %ro%rtis
5' 6oundnss & 6tru"tural 6tabilit#
7' Hat tratmnt
6'6 MEC0ANICAL
0' Thi"*nss o! Matrial
2' Dimnsion & No' o! "om%onnts
6'7 "ROCESS
0' A&ailabl !orms o! "onsumabls
2' Ada%tabilit# !or th 8ob
3' +ldin$ %ro"ss sl"td
6'2'2 8ASE MATERIAL
Th sin$l im%ortant !a"tor dtrminin$ th sl"tion o! !illr mtal and %ro"ss
is bas matrial s%"i!i"ation bin$ 8oind' Th bas matrials ar "lassi!id as
%r A6TM s%"i!i"ation'
In $nral th bas mtals ar broadl# "lassi!id as Carbon 6tl- LA6- 66 and
Hi$h Allo# 6tls' In addition thr ar othr stls !or lo( tm%ratur
a%%li"ation- . & T 6tls t"'- !or s%"i!i" a%%li"ation'
6'2'6 MEC0NICAL "RO"ERTIES
M"hani"al %ro%rt# o! (ld mtal basi"all# "o&rs th as%"t o!-
0' 6oundnss
2' 6trn$th
3' Tou$hnss
Th (ldin$ "onsumabl should b so dsi$nd- so as to b "om%atibl
mtallur$i"all# (ith bas matrial and %rodu" sound (ld to $i& radio$ra%hi"
)ualit# d%osits'
As th (ld mtal has a "ast stru"tur as "om%ard to th rolld stru"tur o! th
bas mtal and (ld zon is li*l# to "ontain d!"ts li* %orosit# and sla$- th
(ld mtal tnsil strn$th is r)uird to b hi$hr than bas matrial' Th +ld
mtal should also ha& ad)uat tou$hnss at s%"i!id dsi$n tm%ratur
ta*in$ in to a""ount !abri"ation %ra"ti"s'
2
6'2'7 C0EMICAL COM"OSITION5
Th +ld Mtal "hmistr# in $nral mat"hs th "om%osition o! bas mtal
!or similar mtal 8oinin$' In "as o! dissimilar bas mtals ar bin$ (ldd-
du "ar should b ta*n to s that dilutd (ld mtal (ill not rsult in
!ormation o! brittl intrmtalli" "om%ounds' Th dsi$n o! (ld mtal
"hmistr# is to b basd on dilutd (ld mtal "hmistr# & its "om%atibilit#'
Th "hmi"al "om%osition o! (ld mtal "an b ntirl# di!!rnt as "om%ard
bas mtal !or o&rla# 9 hard !a"in$ a%%li"ation'

6'2'9 CORROSION "RO"ERTIES:
Th +ld Mtal "orrosion %ro%rtis ar to b )ual or su%rior to that o! bas
mtal' This is to a&oid %r!rntial atta"*s on th (ld 8oint'
6'2': "0;SICAL "RO"ERTIES:
Th Ph#si"al %ro%rtis o! (ld mtal should b "om%atibl (ith that o! th bas
mtal' Ths in"lud %ro%rtis li* th thrmal /%ansion "o;!!i"int- thrmal
and l"tri"al "ondu"ti&itis- ma$nti" %rmabilit# t"'
6'2'< SO4NDNESS AND STR4CT4RAL STA8ILIT;:
Th +ld Mtal should b "a%abl o! rsistin$ som amount o! dilution o! th
bas mtal (ithout !ormin$ a "ra"* snsiti& (ld mtal and th (ld mi"ro
stru"tur should b stabl undr th /%"td sr&i" "onditions'
6'2'=' 0EAT TREATMENT:
Th Consumabls sl"td !or 8oinin$ should b "a%abl o! $i&in$ th dsird
tst rsults in as (ldd "ondition as (ll as hat;tratd "ondition' +hn hat
tratmnt is not s%"i!id in dsi$n9"od- it is &r# ssntial to idnti!# &arious
hat;tratmnt sta$s durin$ !abri"ation and nsur that "onsumabl sl"td
dos mt ths r)uirmnts' Th $nral hat;tratmnt "#"ls n"ountrd
durin$ !abri"ation ar normalizin$ and strss rli&in$'
6'6'2' T0IC>NESS OF MATERIAL:
,or sl"tion o! %ro%r "onsumabl and %ro"ss- thi"*nss o! matrial %la#s a
&ital rol' Th sl"tion o! smi;automati" and automati" %ro"ss "oms into
%i"tur onl# i! bas mtal thi"*nss normall# /"ds 0<mm and 8oint
"on!i$urations ar ada%tabl !or automation'
6'6'6' DIMENSION $ NO' OF COM"ONENTS5
+hil thi"*nss in %rin"i%l d"id th sl"tion o! %ro"ss- th dimnsion o! 8ob
and numbr o! "om%onnts to b (ldd also %la# an im%ortant rol' In "as o!
ha&# sub;assmbls &n thou$h ln$th o! th 8oint ma# b too small !or
automation- i! th o%ration is r%titi& in natur- th sam "an b "onsidrd
!or automation' Th automation not onl# rdu"s th "ost but also im%ro&s th
)ualit# o! 8obs'
3
6'7'2' A-AILA8LE FORMS OF CONS4MA8LES5
As #ou (ill all a$r- this is sin$l most im%ortant !a"tor !or sl"tion o!
%ro"ss' On" th t"hni"al dtails ar (or*d out and suitabl "onsumabl
s%"i!i"ations ar idnti!id- it is ssntial to !ind out (hthr "onsumabls ar
radil# a&ailabl !or 6MA+- GMA+- ,CA+ &9or 6A+ b!or %ro"ss
sl"tion "ould b startd' At %rsnt- than*s to t"hnolo$i"al d&lo%mnt- in
$nral !or all "ommon matrials 6MA+- 6A+ & ,CA+ "onsumabls ar
radil# a&ailabl'
6'7'6' ADA"TA8ILT; FOR T0E ?O85
1!or !inalization o! th t#% o! "onsumabl to b usd- it is ssntial to stud#
(hthr th 8ob is bin$ don in th (or*sho%- sit or sub;"ontra"tor=s %rmiss-
so as to as"rtain a&ailabilit# o! suitabl )ui%mnt and also ta* into
"onsidration n&ironmntal "ondition'
6'7'7' SELECTION OF "ROCESS5
Th %ro"ss sl"tion o! "ours is basd on a&ailabilit# o! suitabl "onsumabls
in addition to ta*in$ into "onsidration thi"*nss o! "om%onnts- dimnsions-
numbr o! "om%onnts also ada%tabilit# o! th %ro"ss !or th 8ob'
+ (ill no( loo* at &arious %ro"ss o%tions a&ailabl su"h as 6MA+- 6A+-
GMA+ & ,CA+ > Ad&anta$s & Limitation o! a"h o! abo&'
6'7'7'2' S0IELDED METAL ARC WELDIN, @SMAWA5
Ad#anta.es5
a) Variety of electrodes with different features:
As !lu/ "oatin$ ma*s it %ossibl to "ontrol (ld mtal "hmistr#- most (id
ran$ o! "onsumabls manu!a"turd
Most versatile in use-all-position joints/joints with limited access
This is du to all %osition "a%abilit# o! "onsumabls- as o! o%ration & also
a&ailabilit# o! )uali!id %rsonnl=s & )ui%mnts.
a) Suitable for most alloys
This is /tnsion o! a&ailabilit# o! suitabl "onsumabls'
b? Euipment simple! ine"pensive # portable.
Disad#anta.es5
a? $inite len%th
Consumabls ar manu!a"turd in !i/d ln$ths o! 45<935<;mm' Hn" %ro"ss
inbuilt (ith r%atd sto%s- (hi"h rsults in lo(r %rodu"ti&it#'
b) &i%h dependence on welder s'ill
Trainin$ o! (ldr is most "riti"al as%"t !or su""ss!ul a%%li"ation
c) (ot amenable to automation
4
Du to !init ln$th o! "onsumabls- it is ssntiall# labour intnsi& %ro"ss
6'7'7'6 ,AS METAL ARC WELDIN, @,MAWA5
Ad#anta.es5
a) )ontinuous electrode
D&lo%mnt to(ard automation (hrin "onsumabl is su%%lid "ontinuousl#
b) &i%her current possible
E&n thou$h th "onsumabl diamtr is smallr i'' 0'290'7 mm hi$hr "urrnt
"an b usd du to hi$hr s%d o! (ldin$ @+ir !d rat?
c) &i%hly amenable to automation
In &i( o! "ontinuous (ir !d- "an b automatd basd on s%"i!i" a%%li"ation
Disad#anta.es5
a) Special Euipment reuired which is mar%inally costlier their SM*+
b) +elder s'ill dependence still hi%h! especially for out-of-position weldin%
c) (ot amenable to customi,ation
*s weld metal chemistry will be same as wire chemistry
6'7'7'7 S48MER,ED ARC WELDIN, @SAWA5
Ad#anta.es5
a) &i%hest deposition rate
1in$ automati" %ro"ss th "urrnts "an b st at 3<< to 0<<< am%s d%ndin$
on siz o! (ir- a%%li"ation & hn" hi$h d%osition rats.
b) Most suited for automation
As %ro"ss- it is most suitd !or 8oints ha&in$ s#mmtri"al $omtri"al "ontours
su"h as Lon$itudinal & "ir"um!rntial 8oints
c) )onsumables can be customi,ed
As !lu/ usd in %ro"ss "an b utilizd !or addition o! allo#in$ lmnts- th
"ombination (ir9!lu/ "an b dsi$nd to $i& dsird (ld mtal "hmistr#'
d) -owest operator fati%ue
Du automation th o%rator rol is "on!ind to su%r&ision'
Disad#anta.es5
a) (ot versatile . no positional capability
Not suitabl !or %ositional (ldin$ %arti"ularl# !or Arti"al & O&rhad
%ositions'
b) /enerally not used for thin sections
R"ommndd !or thi"*nss b#ond B mm
c) 0oint fit up very critical
In &i( o! hi$hr "urrnts bin$ usd- mismat"h & /"ssi& $a% (ill rsult in
1urn throu$h'
d) *rc not visible. &ence joint or seam trac'in% may be necessary
E/a"t (ldin$ lo"ation is not &isibl du to !lu/ "o&rin$' Hn" /trnal
$uidan" to !ollo( 8oint "ontour r"ommndd a"hi&in$ .ualit# +lds'
5
6'7'7'9' FL4B CORED ARC WELDIN,
,CA+- (hi"h is also *no(n as Insid;Out as "om%ard to 6MA+- has mr$d
as most &rsatil tool in th hands o! +ldin$ En$inr du to !ollo(in$
rasons'
a) &i%h 1roductivity of )ontinuous +ire +eldin%.
As "om%ard to 6MA+ %ro"ss- ,CA+ is a "ontinuous (ir t#% %ro"ss
$i&in$ hi$hr %rodu"ti&it#'
b) Metallur%ical benefit of the $lu"-2ailor made )hemistry
In addition to bin$ "ontinuous (ir (ldin$ %ro"ss- addition o! !lu/
ma*s it %ossibl to %rodu" (ir $i&in$ (ld mtal "hmistr# to &arious
6%"i!i"ations usin$ sam t#% o! stri%'
&i%her )urrent than Solid +ire
Th ,CA+ "an us hi$hr "urrnt than solid (irs as !lu/ 6hildin$ $i&s lssr
hat dissi%ation & also lo(r s%attr l&l'
c)&i%h 3uality 4adio%raphy +eld 5eposits
Th "a%abilit# to us Hi$hr Currnts "ou%ld (ith small diamtr o!
(ir ma*s it %ossibl to a"hi& bttr sid(all !usions &n in Narro(
Groo&s' This also hl%s in sl"tin$ su%rior 8oint dsi$n to rdu"
o&rall +ld mtal d%osition >thus rdu"tion in "ost o! !abri"ation'
d)Versatile 6se-*ll 1ositional! +ide 2hic'ness 4an%e
Th most im%ortant !a"tor d"isi&l# in !a&or o! ,CA+ is its %ositional
"a%abilit# as "om%ard to GMA+ &n (hn t#%i"al s%"i!i"ation o!
GMA+ (ir is a&ailabl' Also a&ailabilit# o! ,CA+ in 0'2mm- 0'7 mm
& 2'<mm ma*s it %ossibl a%%l# th %ro"ss to (id ran$ o! Thi"*nss
as "om%ard to 6A+'
e)Visible *rc -Easy to 6se
In ,CA+ as "om%ard to 6A+- th ar" is &isibl & hn" rsults in +ldr
Com!ort9as o! o%ration'
Disad#anta.es5
a) Special Euipment reuired which is mar%inally costlier their SM*+
b? $)*+ wires more e"pensive on wei%ht basis but compensated by hi%her
productivity.
E&n thou$h (ir "ost is mu"h hi$hr on C$ basis- ta*in$ into "onsidration
Produ"ti&it#' ,CA+ b"oms "onomi"al !or Industris ha&in$ hi$hr ,i/d
Cost
7'3 ANAL;SIS5
Ta*in$ into "onsidration &arious %ro"ss ad&anta$s & limitations- !ollo(in$
%oints "an b hi$hli$htd'
D,or (ldin$ o! C69LA6 & 66 in most "ass as all th %ro"ss "onsumabl ar
radil# a&ailablE th %ro"ss limitation is !inall# di"tatd b# !ollo(in$ "ritria'
7
6MA+ 6A+ GMA+ ,CA+
D%' Rats 4 0 3 2
Go' 6#mmntr# 4 0 3 2
Positional +ld 2 ; ; 0
,ild Foints 2 ; ; 0
Di!!i"ult ,ild Foint 0 ; ; 2
Cod: @0? Ar# Good @2? Good @3? 6atis!a"tor# @4? Lo(
D,or (ldin$ o! allo# stls & s%"ial "om%osition hi$h strn$th stl
onl# 6MA+- 6A+ & ,CA+ "onsumabls ar radil# a&ailabl'
D,CA+ "onsumabls "an also b dsi$nd to b usd (ith !lu/ !or
6A+ a%%li"ation'
Th us o! ,CA+ !or ,abri"ation o! Carbon 6tl- Allo# stl- .&T hi$h
Tnsil 6tls & 6tainlss 6tl (ill not onl# rsults in !astr Produ"ti&it# but
also #ilds )ualit# (lds (hi"h do not r)uir an# !urthr (or* li* $rindin$
&!inishin$ o! +ld Foint' Th o%rational as- (hi"h is "hara"tristi" o!
,CA+ %ro"ss- nsurs us o! hi$hr "urrnts (hil (ldin$'

9'3 T;"ES OF CORED WIRES:
aA ,as&ess @Se&) Shie&ded?:
T#%s o! "onsumabls a&ailabl in this $rad in"lud ,abri"ation +irs
!or out door a%%li"ation- 6tainlss +irs & also R&M Allo#s' Th
Gaslss t#%s o! (irs ar normall# a&ailabl in 0'7mm to 2'4 mm'
bA,as Shie&ded 5
In this t#% o! (irs in addition to shildin$ %ro&idd b# ,CA+ in !orm
o! sla$ "o&r & %ro"ss $ass $nratd- /trnal $as li* CO2 or mi/d
$as "o&r is usd' Ths t#%s o! (irs ar mostl# usd !or !abri"ation
a%%li"ation' Th additional $as "o&r nsurs "lanr (lds o!
radio$ra%hi" )ualit#'
cA Composite Sbmer.ed Arc 5
Ths t#%s o! (irs ar /trml# %o%ular !or s%"i!i" (ir "hmistr#
r)uird in smallr lots' Mostl# usd in "ombination (ith ,usd or
Nutral !lu/ to $t dsird (ld "hmistr#'
dA Meta& Cored 5
N(r $nration o! (irs s%"iall# dsi$nd !or Roboti" a%%li"ation'
Th %rodu"t #ilds &r# lss or no sla$ "o&r- (hi"h a&oids on "lanin$
o%ration in Roboti" a%%li"ation' Also %o%ular in "losd n&ironmnt
(ldin$ du to hi$h d%osition !!i"in"# & lo( l&l o! smo*
All th abo& t#%s o! +irs ar radil# a&ailabl indi$nousl# & bin$
usd on r$ular basis b# Indian +ldin$ Industris'
G
:'3 T0E "RESENT TREND
Th su""ss in toda#=s "om%titi& businss is Produ"ti&it# & t(o (a#s to
im%ro& Produ"ti&it# ar-
a? Rdu"in$ Labor Cost
b? In"rasin$ Produ"tion 6%d
,CA+ (irs ar "a%abl o! a"hi&in$ th sam in all %osition & also
maintain $ood )ualit#'
In Indian s"nario mor than B< H o! (ldin$ is still bin$ don (ith
6MA+ @6ti"*? & about B H b# automati" %ro"ss i'' 6A+' Th shar o!
,CA+ &GMA+ Pro"ss is about 0<H la&in$ 2H to othr %ro"sss' As
"om%ard to this- th $lobal s"nario r$ardin$ a%%li"ation o! Pro"ss is
indi"atd hr blo('
?A"AN E4RO"E 4SA INDIA
SMAW 789 :89 :;9 <89
,TAW 79 79 79 79
SAW <9 <9 <9 <9
,MAWCFCAW =89 >89 ;;9 ?89
In India th ,utur trnd is /%"td to b as indi"atd blo(:
; 6tad# in"ras in solid &"ord (ir "onsum%tion
; Co&rd El"trod "onsum%tion (ill d"lin &stabiliz around 5<H
; In d&lo%d "ountris th CO2 (ldin$ a""ounts !or mor than 5<H &
India (ill also !ollo( this trnd to "at"h (ith Intrnational Produ"ti&it#
norms'
<'3 COSTIN,5
In an# ,abri"ation- th "ost o! a !abri"ation is di&idd into th !ollo(in$ hads:;
a? ,i/d Cost li*
I Foint Pr%aration
I ,i/turin$
I Ta"*in$
I Pr;Hatin$
I Clan;J%
I Ins%"tion
Th &ariabl "osts in&ol&d basd on Pro"ss bin$ sl"td ar-
a? E)ui%mnt Cost
b? El"trod Cost
"? Labor &O&rhad Cost
B
Th E)ui%mnt & El"trod Cost "onstituts around 4;5 H & B;0<H o! &ariabl
"ost rs%"ti&l# (hras Labor &O&rhad "ost "onstituts B<;B5 H' As !i/d "ost
rmains sam !or all %ro"sss- th rdu"tion in Labor &O&rhad "ost must brin$
in o&rall "onom# o! an# !abri"ation "ost'
In Tabl 0 & 2- Currnt Dnsit# o! &arious %ro"sss & also "ost "om%arison
bt(n 6MA+- GMA+ & ,CA+ at o&rhad "ost o! Rs'3<< %r hour is
hi$hli$htd' It is "lar !rom !i$urs that ,CA+ b"oms "onomi"al %ro"ss &n
thou$h %r C$' Cost o! ,CA+ is hi$hst' Also Tabl' 0 "larl# indi"ats that &n
thou$h sam "urrnt sttin$s ar usd !or all %ro"sss i'25< am%s' Th Currnt
Dnsit# is mu"h hi$hr !or ,CA+ i'' 34< am%s9s)'mm & hn" hi$hr d%osition
rats'
='3 App&ication
,CA+ %ro"ss a%%li"ation !inds (id ran$ o! Industrial Jsa$s (hrin
%ositional a%%li"ations ar in&ol&d' Rad# a&ailabilit# o! di!!rnt t#%s o!
"onsumabls to &arid s%"i!i"ation "ou%ld (ith as o! a%%li"ation ma*s ,CA+
!irst "hoi" o! ,abri"ation En$inr' Hr blo(- som o! th t#%i"al a%%li"ations
ar hi$hli$htd'
a? ,abri"ation Industris
b? Corrosion rsistan" o&rla#s
"? Hard !a"in$ 9 R%air & Maintnan"
G'0 Fabrication Indstries
Th trm ,abri"ation Industris in"luds th 1oilr & Prssur Assls r)uird !or
Chmi"al- ,rtilizr- O!! shor- 6hi%build- Ra( Matrials- Trans%ortation & Othr
ha&# stru"tural !abri"ation a"ti&itis' All su"h industris nds "lassi!id (irs o!
C6- LA6 & Hi$h allo# 6tls "on!ormin$ to A+6'
As ,CA+ "onsumabls ar a&ailabl radil# to mt !ull ran$ o! s%"i!i"ation th
sam "an b usd !or 8oinin$ o!-
; 6imilar stls
; Dismilar stl

='6 Corrosion Resistance O#er&a!
Th d&lo%mnt o! t"hnolo$# & manu!a"turin$ %ro"ss has mad it %ossibl to
ha& "orrosion rsistan" o&rla# usin$ ,CA+ %ro"ss not onl# !or 66 but also !or
but also !or a%%li"ation in&ol&in$ Ni"*l- Monl- Cu%ro Ni"*l & In"onl' Th as#
a&ailabilit# o! "onsumabls is r)uird )uantit# ma*s ado%tion o! ,CA+ %ro"ss
ad&anta$ous'
='7 0ard Facin. C Repair $ Maintenance
This is n(r !ild(hr in ,CA+ has mad trmndous %ro$rss' This a%%li"ation
has t(o distin"t "at$oris'
K
; H, !or OEM a%%li"ation
; H, !or R%air & Maintnan"
G'3'0 0F )or OEM app&ication
This s$mnt in&ol&s H, a%%li"ation on OEM s$mnts li* 6ho&ls- Dozrs &
6harin$ blads as (ll as &al& satin$ sur!a"s'
This basi" "on"%t is to a&oid hi$h "ost Allo# 6tl matrials- (hi"h in&ol&s Hat
tratmnt "#"l !or a"hi&in$ dsird hardnss' Instad som OEM manu!a"turrs
in arth mo&in$ s"tion ar sl"tin$ Carbon 6tl matrials to b hard !a"d (ith
suitabl ,CA+ "onsumabls insitu' This not onl# rsults in "onomi"al altrnati&
solution but also hl%s to a&oid distortiom %roblms asso"iatd (ith HT "#"l'
In othr ara o! s%"ilisation th &al& sats ar bin$ stllitd usin$ ,CA+ (ir'
Th rsults ar said to b n"oura$in$ as o&rall thi"*nss o! o&rla# has bn
rdu"d (ith bttr homo$nous mi"rostru"tur'
Thus abilit# o! ,CA+ to $i& r)uird Chmistr# o! (ld mtal is bin$ !ull#
utilisd !or Industrial a%%li"ation'
G'3'2 Hard!a"in$ !or R%air and Maintnan"
,or &arious Industrial s$mnts li* 6u$ar- Cmnt & Coal mins t"- th
"om%onnts usd !or "rushin$ & sizin$ th ra( matrial undr $o r$ular (ar &
nd to b rbuilt' +ith a&ailabl t"hni"al *no( ho( & also utilization data
a&ailabl th R & M is d&lo%in$ into !ir s"in"' Th R & M o! "om%onnts
(hi"h ar normall# hi$h Carbon 9 Chrom matrial $i&s mtallur$i"al "halln$ !or
rbuildin$ (hi"h has to b %lannd ta*in$ in to "onsidiration'
; 1as mtal "om%osition
; T#% o! (ar
; 6ur!a" "ondition
,or a%%li"ation H, on su"h "om%onnts it is r)uird to "onsidr !ollo(in$ as%"ts'
; T#% o! Ra( matrial bin$ $round
; Abrasi& "hara"tristi"s
; Im%a"t load bha&iour
Ta*in$ in to "onsidration abo&- suitabl t#%s o! "onsumabls ar to b !inalisd
!or build;u%' In man# "ass "ombination o! "onsumabls ar usd to "om%a"t
rosion & im%a"t load r)uirmnts'
It is most "ommon to us 2'4 Dia 9 2'B Dia O%n ar" ,CA+ H, "onsumabl !or
R & M a%%li"ation (hr in 7 >B C$ (ld mtal %r hour is d%ositd' Th r;
buildin$ o%ration in In;situ r)uirs inno&ati& "on"%ts to b ado%td to a"hi&
dsird rsults in shortst %ossibl tim'
0<
D'3 CONCL4SION:
1asd on th %rsnt industrial s"nario !ollo(in$ %oints "an b hi$hli$htd'
; Industris ar ado%tin$ ,CA+- as %rodu"ti& %ro"ss- (hi"h "an $i&-
dsird )ualit#'
- Th a&ailabilit# o! C6- LA6- 66 & H, "onsumabl in India has im%ro&d
in last 5 #ars & bin$ ado%td in ,abri"ation & R%air & Maintnan"
Industris'
; Th %rsnt %ro"ss shar o! GMA+ L ,CA+ (hi"h is at 0<H is
(itnssin$ stad# in"ras & /%"td to ra"h 2<H b# #ar 2<<5'
; As th Industrial a%%li"ation o! 6A+ has alrad# ra"hd 0<<H
utilization l&l- th ,CA+ a%%li"ation (ill ha& ra%id $ro(th' This
(ill also b hl%d b# lo(r "a%ital )ui%mnt in&stmnt "ost'
; Th rad# a&ailabilit# o! %rodu"ts to intrnational standards as (ll as
"ustom built %rodu"ts (ill nsur ado%tion o! ,CA+ as %ro"ss (hr in
%rodu"ti&it# & "onsistnt )ualit# ar basi" r)uirmnt'
Tab&e 2 E "ROCESS COM"ARISON
SMAW ,MAW FCAW
Consmab&e Dia' @mmA 4'< 0'2 0'2
Crrent Settin. 5Amps 25< 25< 25<
Crrent Densit! AmpsCS*mm 2< 22< 34<
TA8LE 6 E COST COM"ARISON E TEC0NICAL DATA
FCAW SMAW ,MAW
Labor $ O#erhead COMPANY 6PECI ,IC M
E&ectrode Cost RsC>. 05< 7< 5<
Dep'Rate >.C0r 5'< 2'< 3'<
Dep'E))icienc! <'BG <'75 <'BK
Operatin. Factor <'45 <'3< <'45
,as F&o( Rate L"M 07 NA 07
,as Cost RsCLtr <'<4 NA <'<4
"o(er Cost RsC>W0 4 4 4
00
FCAW SMAW ,MAW
-o&ts 2B 2B 2B
Amps 3<< 25< 25<
Re(or/ F 3 B 5
We&d Meta& Cost C>.
GO0 o) Rs'733 4<< 0-35< 7<<
TA8LE I-
WELD METAL COST FORM4LAS
0' LA1OR & OAERHEAD N LA1OJR & OAERHEAD CO6T 9 HR

DEPO6ITION O OPERATING
RATE @CG9HR? ,ACTOR
2' ELECTRODE N ELECTRODE CO6T9CG

DEPO6ITION E,,ICIENCY
3' GA6 N GA6 ,LO+ RATE O GA6 CO6T
@LITRE9MIN? PER LITRE

DEPO6ITION RATE @CG9HR?
4' ,LJO N ,LJO CO6T 9 CG O 0'4
DEPO6ITION E,,ICIENCY
5' PO+ER N CO6T9C+H O AOLT6 O AMP6
0<<< O DEPO6ITION RATE
TOTAL CO6T PER CG O,
DEPO6ITED +ELD METAL N 6JM O, 0 > 5 A1OAE
GGG
02