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PROCESS OF MANUFACTURE FOR WELDING

ELECTRODES
DETAILS OF EQUIPMENT FUNCTIONS:
WIRE DRAWING
In theses machines, Wire rod of size 5.5mm or 6.35 will be drawn to required standard size
2.5 mm, 3.2 mm, 4.00 or 5 mm
WIRE STRAIGHTENING AND CUTTING MACHINE
These machines straighten and cut coils of wire into the required standard length. The tolerance on
length is accurately maintained.
DRY MIXER
The powders which constitute the flux are mixed together in the mixer so that the constituents are
blended into a homogeneous batch.
WET MIXER
In this machine the dry mixed flux and binding agent ( Potassium / Sodium silicate ) in measured
quantity are mixed and kneaded to get a wet paste and this wet paste will be transferred to
briquetting press.
BRIQUETTING PRESS
The past obtained from the kneading machine is compressed into cylindrical cakes which can be fed
neatly into the extrusion cylinder
WIRE FEEDER WITH WIRE HOPPER
This equipment can be set and reset with ease for different diameters and lengths of electrodes. One
complete set of change over parts is provided to enable production of 2.50mm, 3.15mm, 3.25mm,
4.00mm and 5.00mm change over parts consist of pickup rollers, wire guides, guide tubes mouth
pieces. All change over parts are made out of hardened and tempered alloy steel. The wire feeder
systems is driven by a train of gears through a gear box. The speed of the wire feeding is adjustable.
EXTRUDER
The extruder is equipped with a hydraulic cylinder, hydraulic pump, pressure control valve and
directional control valve. The piston has a fast return stroke to enable fast raffling of the paste
cylinder. The paste cylinder has dia meter of 150 mm and the stroke of the paste piston is
approximately one meter The following is the mechanism of operation of the wire feeder / extruder.
The pieces of wire which are ejected from the wire feeder at high speed pass through the press
block and there after through the coating die. Simultaneously the paste is compressed through the
press block, takes a right angle turn and covers the space between the coating die and the wire.
Thus the bare gats the coating.

CONVEYOR
The conveyor takes over the coated electrode from the transfer belt and performs the following
operation
1.Spacing the electrodes apart
2. Aligning the electrodes
3.Brushing the bare ends
4.Grinding / Brushing the arc striking ends
After the above operation are done, the electrodes are taken over by a slower belt from where they
are manually lifted and placed on trays. The quality of workmanship and the alignment of various
moving parts will be such as to maintain a low rejection level on the conveyor.
BAKING OVEN
The baking oven is of the walk-in type so that the trollies can be pushed in and out. A spare set of
trollies is provided as standard accessory and the oven is manufactured specially to cope with the
feed drying of electrodes.
DE COATING MACHINE
This equipment enables the coating of rejected / damaged electrodes to be separated from the core
wire so that both the wire and the flux may be recycled.
PACKING TABLES
These tables enable quick manual packing of electrodes, segregation of damaged electrodes and
filling up of good electrodes in polythene bags / cartons.
MICROMETER FOR CONCENTRICITY MEASUREMENT
This instrument can measure the concentricity of the semi-dry green coating on the electrodes to an
accuracy of 0.10 mm.
CHEMICAL & MECHANICAL LAB
A complete set of laboratory equipment for wet analysis and mechanical testing equipment
comprising of Rockwell hardness tester & charpy / lzod impact tester and universal testing
machines may be provided as optional extras.

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