Fluxes:

Fluxes are granular fusible mineral compositions.

The flux is specially formulated in combination with a special electrode wire type so that the desired mechanical properties are achieved.

The flux shields the molten weld pool from the atmosphere while simultaneously adding alloying elements and removing tramp elements and oxide inclusions in the weld metal, to the slag.

Active flux:
Fluxes may be referred to as active if alloying elements are added to the weld.

Neutral Flux:
Neutral if its purpose is to act as a protective cover over the molten weld.

The slag so formed is then removed after welding to produce a clean refined weld metal, free from porosity or inclusions and with good mechanical properties and strength.

Through a choice of our Sure-flux and a wide range of wires, and precise control of welding current, arc voltage and wire feed rate, extraordinary control of mechanical and metallurgical properties of the weld is possible, resulting in superior and quality weldments.

Types of Fluxes manufactured at S. Chems & Allied Producers: -

Fused: This ismanufactured by mixing various minerals and melting them in a Submerged Arc Furnace. The molten product is then quenched in water and the granular product ground down to the required size fraction.

This results to an ideally mixed Homogeneous Mineral Composition which controls weld metal hydrogen and provides consistent welding properties.

Agglomerated: These are product by granulating a mineral mixture with a Binding Reagent such as Sodium and Potassium Silicate.

The granules are then calcined and sized into the required mesh size.

Welding Stick Electrode Fluxes: These are produced by blending various Minerals & Ferro Alloys to a homogeneous Mix Composition.

Submerged Arc Welding:

Submerged Arc Welding (SAW) is a mechanised high speed, high disposition rate welding process. The arc is struck between a continuously fed bare or copper coated wire, electrode and the work-piece, both submerged under a blanket of granulated mineral composition – The Submerged Arc Welding Flux. The layer of flux on fusion generates the gases and the slag protects the weld pool and hot weld metal from the atmospheric contamination. The Arc moves along the joint and as it does so excess flux is recycled via a pnuematical conveyor to hopper.

The remaining fused slag layer is peeling and can be easily brushed away after welding. As the arc is completely covered by the flux layer, heat loss is extremely low. This produces a thermal efficiency as high as 60% (compared with 25% for manual metal arc welding). There is no visible arc light and hence the name – Submerged Arc Welding. The Welding process is clean, and virtually free from smoke or spatter.