Welding is a procedure or process that uses fusion to unite materials, primarily metals. Welding involves melting base metal and typically adding a filler material to the junction to generate a pool of molten material – the weld pool – that cools to form a weld that is usually stronger than the base material.
Welding electrodes are used in the Arc welding process, in which an electrical current run between the electrode and the base metal, generating enough heat to melt both the electrode and the base metal. In this procedure, a flux-coated electrode is employed. As the electrode melts away, the electrode holder retains it in place. Slag is created when flux melts and protects the weld puddle from contamination by the atmosphere.
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Market Opportunities and Marketing Concerns
Welding electrodes have a wide range of applications in all production processes. These are also perfect for repairs, where welding is likely the only way to save broken or worn-out metal parts.
The demand for welding consumables is linked to the country's steel consumption. The welding consumables market in India is expected to be driven by end-use sectors such as transportation, building & construction, oil & gas, and electricity in the near future. The massive expansion of India's construction, shipbuilding, and energy industries, particularly wind power, will emphasize the significant growth of the Indian welding market. Due to technological improvements and the wide growth of end-use industries, the demand for welding consumables in India is expected to develop rapidly. By the end of 2020, the Indian welding consumables market is expected to grow from Rs 30.88 billion in 2013 to Rs 45.37 billion. The welding consumables market is predicted to increase at a CAGR of 10-11 percent over the next five years, owing to the strong outlook of the infrastructure sector. When compared to manual electrodes, continuous electrodes will grow faster.
Welding consumables account for almost 25% of the growth in the end user industry of automobiles and transportation. Over the forecast period of 2014-2020, the construction/ infrastructure and electricity sectors are predicted to increase at a faster rate. Other applications, such as marine / shipbuilding and general fabrication, are expected to grow at a moderate rate over the next few years.
Due to its nearly universal application and consumable nature, a welding project has a lot of potential. A high-quality producer will have a great chance of succeeding, even in a largely competitive market.
Manufacturing Process
Wires of various gauges are drawn from wire roads of 6 mm or 8 mm to generate several sorts of electrodes. The needed size of drawn Electrode grade wire is first straightened in a straightening machine, then cut to size and stored.
The flux is made in a dry blender and a wet mixer according to the formula. Coating fluxes for shielded arc electrodes come in a variety of kinds, each with its own set of effects during the welding process. The coatings of mineral substances, which leave a layer of slag, generate a layer of gas to protect the weld zone, whereas the coatings of cellulose generate a layer of gas to protect the weld zone.
The automatic slug press then produces a cylindrical slug of flux material. The slug is then placed in the extrusion press, and straight cut wires are fed through it, with the extrusion press pushing the wire through the slug and pressing it to give it a uniform coating. Flux-coated core wire rod is conveyed and collected at the end of the process. These flux-coated rods are then placed in a drying oven to dry. After drying, the electrode batch is subjected to sample testing before being packed and dispatched.
The method of producing continuous flux coated and flux core wires, which might be called product diversification. The manufacturing method is identical, with the exception that flex coating/filling requires in-line flux curing ovens and the core filled system necessitates the shaping of metal strip into a flux filled tube.
Welding electrodes should be subjected to mechanical, metallurgical, and chemical testing on a regular basis, and a testing laboratory should be set up. Tensile test, hardness test, impact test, chemical test, bending test, microscope test, moisture content test, and other quality control tests will be performed.
How to get Pollution Certificate/NOC
Every business entity interested in establishing a manufacturing unit for welding electrodes must first get a prior approval form Concerned State Pollution Control Board (SPCB)/Pollution Control Committee (PCC). No person shall develop or operate any industrial facility in an air pollution control area without the prior authorization of the State Pollution Control Board (SPCB)/Pollution Control Committee (PCC) under the provisions of the Air Act 1981 and the Water Act 1974. According to the guidelines of the Central Pollution Control Board (CPCB), industries in India are classed as Red, Orange, Green, or White, and each state/UT has its own set of classifications based on their location. Manufacturing of Welding Electrodes come under orange category and following certificate will be issued by Pollution Department.
What are the important documents and Information required to get Pollution Certificate/NOC
What is the procedure to obtain Pollution certificate/NOC /Authorization
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