Production Precautions for Flux-Cored Welding Wire Production Line
In the production of flux-cored welding wire, every step from raw materials to finished product packaging is crucial. Neglecting any link can directly affect the quality of the final welding wire and the welding effect. The table below summarizes the key considerations for each stage of the production line, helping you quickly grasp the essentials.
| production link | Core considerations |
|---|---|
| 📦 Raw material preparation |
- Steel strip: Dimensions and thickness must be uniform; width deviation should be controlled within ±0.1mm, and thickness deviation within ±0.01mm. The surface should be free of rust, scratches, severe bending, and burrs and cracks on the edges. Clean the surface of grease and dust before use. - Powder: Accurately weigh and thoroughly mix according to the formula. Dry as required to remove moisture and prevent welding porosity. Store dried powder properly at a cool, dry place to prevent re-absorbing moisture. |
| ⚙️ Steel strip forming and filling |
- Forming and Joining: The steel strip is gradually rolled into a U-shape using multiple pairs of rollers. It is essential to ensure the welding wire join is straight, and its position should be controlled directly above the welding wire cross-section to avoid deflection. - Powder Filling: Ensure the powder is evenly filled within the U-shaped groove of the steel strip, avoiding delamination or jagged edges. Maintain a stable filling rate, with a deviation preferably within 0.5%. . |
| 🔧 Drawing reduction |
- Drawing Process: Multiple drawing processes are required from semi-finished product to finished product. The total reduction rate needs to be reasonably allocated, with the reduction rate of the first drawing stage being relatively small. - Lubrication and Cleaning: Select a lubricant suitable for flux-cored wire. After drawing, use dry methods (such as felt pads or scouring pads) to polish and remove residual lubricant from the surface, ensuring a smooth wire surface. |
| 📮 Welding wire winding and packaging |
- Winding: Large-diameter I-beam reels are recommended for winding to reduce the radius of curvature of the welding wire. Ensure tight, neat winding without sharp bends, kinks, or wavy patterns to guarantee continuous wire feeding during welding. - Packaging and Moisture Protection: Welding wire is typically sealed in a plastic sleeve with a desiccant, then placed in a cardboard box or drum before shipping to prevent moisture absorption. |
| 🛡️environment and people |
- Environmental Control: Maintaining a clean and dry production environment is crucial for the production of both the flux powder and welding wire. - Equipment Maintenance: Regularly clean and lubricate equipment to ensure its proper functioning. - Operating Procedures: Operators must be trained to understand and master the basic knowledge and operating skills of the equipment. |
💡 Key Control Points for Quality Improvement
In addition to the precautions mentioned above, the following key points are particularly important for ensuring the quality stability of the final product:
Strictly control the quality of the steel strip: The steel strip is the "skeleton" of the welding wire, and its quality directly determines whether production can proceed smoothly. Besides the dimensional and surface requirements mentioned in the table, the camber (the degree of non-straightness of the side edge) of the steel strip also needs to be carefully controlled. It should not exceed 1mm over a 1000mm length; otherwise, it is very easy for the strip to deviate during rolling and drawing, causing production interruptions.
Ensure the homogeneity and dryness of the flux powder: The flux powder is the "soul" of the welding wire, and its uniformity and dryness are paramount to avoiding welding defects (such as porosity and cracks).
Homogeneity: Unevenly mixed flux powder can lead to fluctuations in the chemical composition of the weld, affecting weld quality.
Dryness: Moisture absorption by the flux powder is one of the main causes of weld porosity. Therefore, the exposure time of dried flux powder to air during transportation and filling needs to be strictly controlled to prevent secondary moisture absorption.
Precise Control of Drawing Process: Drawing is the core step in reducing the diameter of the semi-finished welding wire to the target diameter. This process requires meticulous planning, rationally distributing the total reduction rate to each drawing die. Improper reduction rate distribution, especially excessive reduction in the first drawing pass, can easily lead to abnormal wire shape or even breakage.
Flux-cored wire Welding Machines Production Line
Raw material: 14 * 1.0mm steel strip, CS
Finished product: E71T1 flux cored welding wire 1.2mm
Forming shape: butt joint
Forming machine steel strip inlet speed during working: 70~80m/min (design max. speed: 110m/min)
Filling rate: 13-16%
Forming initial outlet wire dia.: ~φ4.7mm
Forming finished wire dia.: φ2.5mm
Forming productivity: 5T/8hrs
Fine drawing machine speed during working: 16-18m/sec (design max. speed: 25m/sec)
Fine drawing wire dia.: φ1.2mm
Fine drawing predictivity: 3~3.5T/8hrs
Actual production is related to product filling rate. When the filling rate is low, the production speed is high and the output is
high. When the filling rate is high, the production speed is low and the output is low.
All the machines will be customized based on user industrial voltage.
About the company
Hebei Hylite Machinery Co., Ltd. is located in the center of the Beijing-Tianjin-Hebei economic & technological region - Xianxian Economic Development Zone, where is the birthplace of motto "Seeking Truth From Facts". The factory covers an area of 50 acres. We are engaged in the R&D, manufacturing and sale service of equipment for steel bar and metallic wire processing. The R&D team mainly composed of Chinese and Italian designers. It has a professional global after-sales service team.
What do we supply?
Steel wire drawing machine, cold-rolled ribbed steel bar machine, steel wire stranding machine (prestressed steel stranding machine), prestressed high-strength steel bar wire drawing machine, high-strength steel wire equipment, welding wire production line, steel wire rope machine, steel wire strander, steel bar straightening machine, combined drawing machine, combined wire drawing equipment, steel wire galvanizing equipment, nail making machine, wire mesh machine, spring steel wire drawing machine, PC steel bar equipment, steel bar online shot blasting equipment, NPR steel bar machine, intelligent steel bar machinery, R&D of intelligent machinery software, Customized steel bar processing equipment.
