The domestic status of flux cored wire production equipment and technology flux cored welding wire for welding a variety of products, the rapid rise of its domestic production technology in the end at what level? Flux cored wire manufacturers mainland and Taiwan enterprises and foreign companies than in the end the difference? Why is there such a big price difference? At present, the price gap is relatively large flux-cored wire. Taiwan-funded enterprises of domestic or foreign production of flux cored wire, the price per ton than our flux cored wire production to be higher than the thousand or even more than two thousand yuan! But also by the customers! Flux cored wire can be seen in the quality of our great room for improvement! Mainly in the following two aspects: the drug core formulation and production process. Differences in the production process focused on the design and finished machine wire surface treatment. Taiwan enterprises in the machine rolling mode to use more Canadian way of rolling. The surface of finished wire to go through two processing: a is the surface cleaning process, Another rust treatment is to improve the welding wire feeding and overall performance. We only look at the basic flux cored wire manufacturers in the surface cleaning process. By the author and head of the company's technology to communicate and discover: Shandong De Win welding industry is mature grasp of Taiwan's formula, technology, production process, including the finished surface treatment of flux-cored wire technology and successfully developed a roll model, greatly reduce production costs and improve the quality of the wire. Precision machining and assembly technology is the soul of flux cored wire forming machine. Specificity of the flux cored wire production, the equipment for each part of the processing requirements are very high, perhaps a small part machining accuracy does not meet the requirements will result in the entire line is not stable operation. I once visited the welding industry in Shandong German transport assembly process, skilled workers skilled in the little box into a large box, and tolerance between the two only one or two wire. Almost no gap after installed! Introduction of skilled workers, according to the sophistication of the only way to be able to guarantee the production process does not go the wrong strip, thus ensuring a uniform fill rate. Mainly to see the box part of the selection, there are steel-and cast-type splicing, in which the processing of casting-type deformation rate is small, relatively easy to achieve the required accuracy of the device. As roll is a consumable, the forces shaping the design of machines with roll wear has a direct relationship, so the choice to consider when forming machine this factor. The roll of the design will have some impact on costs, in general, more durable and relatively large diameter. Roll part of the selection does not mean that the higher hardness of the material the better, depending on the molding machine designed for the forces, but also the cost side to choose. Flux cored wire production in China began in the 20th century and the early 90s, a late start, but the 21st century as China's market economy and speed up the industrialization process, welding materials, the general trend is towards the development of "high quality, efficient, automated" direction, the performance of the most prominent of which is the flux cored wire, now become the fastest growing welding consumables. Flux cored wire electrode coating has both adjustable formula, but also have continuous solid wire welding characteristics. Products on display can be seen from, flux cored wire meteoric rise, more and more people of all ages. Welding industry and metallurgical industry are closely related. Apparent demand for welding consumables associated with the steel production and strong demand for welding consumables steel apparent consumption of the whole and show 0.007-0.008:1 features. 2008 production of about 360 National Welding million tons, an increase of about 4%, accounting for about 50% of global production, is truly a welding consumables power. Industry trends: product upgrading, decline in the proportion electrode, welding wire to increase the percentage. Welding automation and demand for diversified products to promote upgrading of the structure of welding materials. Welding has been the automation of the current foreign higher, mainly by hand welding electrode proportion has dropped to below 20%; while the proportion of domestic hand-rod is still up to 60% in 2010 China accounted for welding of the total ordinary electrode has dropped to below 50%. Flux cored wire as a new substitute materials, an increasing proportion of the welding consumables.
Introduction to metal powder type flux cored welding wire First, the characteristics of metal powder type flux cored wire Metal powder type flux-cored Welding Wires which both the real strengths of both high deposition rate and low spatter and so the advantages of slag-type flux cored wire, the most notable advantages are: A: higher deposition rate as the metal powder type flux cored wire is wrapped by the steel powder composition, the current density, melting fast. While the powder metal powder type flux cored wire in a large number of iron, ferroalloy and metal powder, non-metallic mineral content is less, and iron, ferroalloy and metal powder relative to the melting point of low melting point non-metallic mineral powder, making the melting lower energy powder, which the slag than solid wire and flux cored wire with a higher type of deposition rate.
Name diameter deposition rate welding parameters: TEC-70 when the 1.2 210A/28V 52.3g/Min backing The filling 1.2 275A/32V 74.6 g / Min Surface covered when 1.2 335A/34V 94.8 g / Min TM-56 (the same type of solid wire) 1.2 240A/28V 59.5 g / Min Table 1, on the metal powder, solid wire deposition rate of the cf It should be noted that the metal powder type flux cored wire in high voltage high current case, the smoke generated by welding, spatter, and arc column changes, the shape of molten pool does not produce major changes. In contrast, solid wire welding for the use of a large, its bead forming a sharp deterioration in the amount of splash, dust volume will greatly increase the mechanical properties of weld metal will also be affected.
B: higher deposition efficiency
As the metal powder type flux cored wire in the welding process almost no welding slag, spatter, so it is higher than the same type of solid wire, flux cored wire is more common deposition efficiency. Name deposition efficiency current-voltage wire TEC-70 1.2 275A/32V 94.1% TM-56 1.2 250A/28V 93.8% (remove the splash and other attachments) TWE-711 1.2 250A/28V 85.7% Even in the most dominant solid wire deposition efficiency, the metal powder type flux cored wire is also a leading position. Compared with the same type of flux cored wire is even more obvious advantages.
C: better welding molding
Because the metal powder type flux-cored arc good characteristics and low amount of dust and small splash, so that the welding process, you can avoid defects such as welding slag, convenient clean-up each seam. And the visibility of the welding operation, easy control of the operator to better pool shape, better welding effect. While also avoiding the reality of cored wire welding, there's the finger-like penetration. Figure 1, solid wire welds simulation Figure II simulation of metal powder flux cored wire weld Metal powder flux cored wire welding of the transition type for the spray transfer mode, the tiny metal welding fine-grained with excellent wetting, especially in the lap of the sheet metal welding, metal powder type flux-cored wire weld smooth, forming beautiful, even without groove, lap of the plate in the welding zone, the weld can also be the perfect fusion of base metal. D: faster welding speed As the metal powder type flux cored wire with the above three advantages, it can achieve a faster welding speed. Name of current-voltage wire welding speed can be achieved:
TEC-70 1.2 335A/34V 1300mm/Min TM-56 1.2 330A/32V 700 mm / Min TM-70C 1.6 400A/40V 800 mm / Min
In the welding speed, the metal powder type flux cored wire much more than the same type of solid wires. In the course of several experimental tests, the performance of the welding quality indicators. In addition, the metal powder type flux cored wire also has low content of diffusible hydrogen (H4 below), the welding process noise, low dust, no welding slag, etc. (especially for environment-friendly enterprises).
Second, the metal powder flux cored wire and application of the classification
Metal powder type flux cored wire is currently in the world has been widely used in many developed countries, the classification method is also different, with TEC-70, for example, metal powder type flux cored wire in the United States because of their structural type flux cored wire with slag similar to the standard used to be attributed to AWS A5.20 T-1 type in the wire, but the metal powder type flux cored wire used in the operation and performance have similarities with the solid wire, AWS now be classified as of A5.18-94 standard in the E70C-3x and E70C-6xx. In Europe and Japan and other countries and regions will remain classified in the metal powder type flux cored wire flux cored wire for a class, in the protection of the use of gas, they use CO2 gas in Japan, a few cases by 80 â„… Ar +20 â„… CO2, and In Europe they use a rich mixture of argon gas welding(CO2 Gas Shielded Welding Wire).
At present the company's metal powder type flux cored wire are: TEC-70, TEC-80B2, TEC-90B3, TEC-80G. Quite the same type of products: TM-56, TIG-1CM and TWE-811B2, TIG-2CM and TWE-911B3, TM-60. One TEC-70, TEC-80B2 and TEC-90B3 has developed mature, excellent performance, and the remaining R & D test products are constantly TEC-70: instead of solid wire TM-56, because of its good forming and welding characteristics of high-speed welding, etc., especially for machinery and automotive manufacturing, especially for high-speed lines using the welding robot. TEC-80B2 and TEC-90B3: quite the same type of product TWE-811B2M and TWE-911B3M, which is characterized by broadly consistent with the TEC-70.