welding business new give

1. Learnings – Week 2

2. Introduction to Welding
Consumables
• Using the correct consumables in welding helps to create a strong bond between the two metals
involved.
• The consumables used in various welding processes are mainly comprised of filler metals and flux.
• Welding consumables are segmented on the basis of welding technique, consumable type, end-
use industry, and region. Some of the consumable types are:
o Stick electrodes: These are also known as welding rods and are used in SMAW or stick
welding process.
o Fluxes: Flux is a consumable used in welding that provides several functions such as
preventing the molten pool from contamination, stabilizing the generated arc, acting as a source
of adding alloying elements, and helping in increasing the deposition rate.
o Solid Wire: Solid Wire helps in deep penetration while conducting the welding process and
usually has less spatter.
o SAW Wire: SAW wire is used in combination with flux which results in excellent productivity.
o Flux-cored Wires: The gas-shielded FCW requires external shielding gas for welding and the
coating solidifies more quickly than the molten weld material. Self-shielded FCW is more
portable because it does not need an external shielding gas and produces a low level of spatter.

3. Introduction to Welding
Consumables
• Conventional Consumables:
o All the consumables that are manufactured according to the specifications or compositions laid
down by the Bureau of Indian Standards, American Welding Society, EN ISO (EuroNorm), etc.
are labelled as conventional consumables.
o For a particular material, we produce numerous consumables which differ on the basis of their
chemical composition, the mechanical properties they possess, and their application.
• Reclamation Consumables:
o In general, it may be said that any metal part that has been broken or worn out while serving can
be reclaimed by welding.
o These consumables are manufactured according to the type of parent material, their application,
and specific customer requirements.

4. Characteristics of Welding
Consumables
The consumables possess the following characteristics:
• Weld Metal: Smooth weld metal surface with even edges.
• Spatter: Minimum spatter adjacent to the weld.
• Arc: A stable welding arc.
• Penetration: It is the ratio of the width of the weld to its depth.
• Coating: It refers to the coating density of the electrode or wire i.e. heavy,
medium, or light.
• Slag: The slag formed should be easy to remove.
• Deposition Efficiency: It is the ratio of deposited weight to melted weight.

5. Third-Party Approvers & Chemical
Composition of Consumables:
 Third Party Approval means an approval, authorization, or qualification obtained
from a governmental or a non-governmental organization. Our product approvers
are BIS, Indian Navy, Reliance, Adani Infra, and many more.
 The distribution and concentration of elements that comprise a material are known
as the chemical composition of that material.
 For example: A welding electrode is made up of two parts: the actual metal, and the
flux coating. The metal can be mild steel, cast iron, stainless steel, high-tensile
steel, copper, bronze, brass, or aluminium.
 The metal is then wrapped in one of the flux coating types i.e., cellulose or rutile or
basic. The flux coating makes the electrical currents flow more evenly during the
weld.

6. Mechanical Properties of
Consumables:
• The mechanical properties of the metals are those which are associated with the ability of
the material to resist mechanical forces and loads. The mechanical properties are as
follows:
• Tensile Strength: The maximum stress that any material can withstand before destruction
is called it’s UTS or ultimate tensile strength.
• Yield Strength: The point where the metal reaches the limit of its elastic characteristic and
no longer returns to its original shape.
• Elongation: The degree to which a material may be bent, stretched, or compressed before
it ruptures. If a rubber reaches twice its length before breaking its elongation percentage is
100%.
• CVN Impact Strength: The Charpy V-notch (CVN) test is a method for measuring the

7. Mechanical Properties of
Consumables:
• Ductility: The property of a material that enables it to be drawn into the thin wire
with the application of tensile load.
• Brittleness: Brittleness is the opposite of ductility. It is the property of breaking of a
material when subjected to tensile loads.
• Creep: When a metal part is subjected to high constant stress at high temperatures
for a longer period of time, the metal will undergo a slow and permanent
deformation which is known as creep.
• Welding Position: The American Welding Society has defined the four basic
welding positions as Flat, Horizontal, Vertical, and Overhead positions.

8. Classification of Consumables
To ensure consistency in composition and properties between wires from a variety of
manufacturers, specifications have been produced that enable a consumable to be easily
and uniquely identified by assigning a ‘classification’, a unique identification that is
universally recognized. We manufacture consumables as per the following classifications:
• AWS: The American Welding Society (AWS) has a mission to advance the science,
technology, and application of welding along with allied joining and cutting processes,
including brazing, soldering, and thermal spraying. The organization has more than 350
welding codes, procedures, practices, and standards.
• EN: This standard defines general rules for the specification and qualification of welding
procedures for metallic materials. This standard also refers to several other standards as
regards detailed rules for specific applications.
• IS: The Indian Standard which is identical to ISO 15607: 2003 that was issued by the
International Organization for Standardization (ISO) was adopted by the Bureau of Indian
Standards on the recommendation of the Welding General Sectional Committee and
approval of the Metallurgical Engineering Division Council.

9. Classification of Consumables

10. Classification of Consumables

11. Applications of Welding
Welding is employed in various industries as a tool for the regular
fabrication of automobiles, air crafts, refrigerators, etc. along with
maintenance and repair work of broken parts and worn-out
components. A few applications of welding are listed below:
• Construction of Bridges: Section and field assembly of lengths.
• Buildings: Column base plates, trusses, formation of structure, etc.
• Pressure Vessels and Tanks: Clad and lined steel plates, shell
construction, joining of nozzles to the shell, etc.
• Storage Tanks: Oil, Gas, and Water storage tanks.
• Railway Equipment: Under frame, air receiver, engine, etc.
• Piping and Pipelines: Rolled plate piping, Open pipe joints, and oil,
gas & gasoline pipelines.

12. Applications of Welding
• Shipbuilding: Shell frames, deck beams, bulkhead stiffeners, girders to shells, bulkhead webs to
plating, etc.
• Construction of Aircraft: Welded engine mounts, turbine frame for the jet engine, oxidizer tanks,
ducts, fittings, etc.
• Manufacturing of Automobiles: Arc welded car wheels, steel rear axle housing, frame side rails,
brackets, etc.
• Trucks, trailers, Machine tool frames, and cutting tools.
• Household and Office furniture.
• Earth moving machinery and cranes.
• Repair of broken and damaged components of machines such as tools, punches, gears,
shears, press, and machine tools frame.
• Hard facing and rebuilding of worn-out and undersized parts.
• Fabrication of jigs, fixtures, clamps, and other work-holding devices.

13. Product Offered By Us
At D&H Sécheron Private Limited, we have classified our products according to the
AWS, IS and EN ISO codes i.e., Conventional and Reclamation consumables which
are then differentiated according to the material type and their applications. Some of
the products are mentioned below:
• Conventional: For different metals, we produce various consumables with
standardized compositions. Supratherme-R, Supratherme, Indotherme,
Ultratherme, etc are some SMAW electrodes for medium and high tensile steel.
• Reclamation: Customer requirements play a major role in manufacturing these
special consumables. For example, LoTherme 355, LoTherme 352, LoTherme 200,
and many more for carbon and low alloy steels.

14. THANK YOU