Joint-Stock company «SpetsElectrode»

Moscow region department ofRussian scientific and technical Welding Society

WORKING EXPERIENCE OF AN ELECTRODE COMPANY

St.-Petersburg – 2000 – Moscow

JSC SPETSELECTRODE

The art to unite

CERTIFICATES OF FITNESS of:Russia, the Ukraine, Lloyd Register, Maritime Register of Shipping, Gosatomnadzor, the «Moscow Quality» Honorary diploma, Russian and Ukrainian Hygienic certificate

manufactures and distributes more than 130 grades of high quality

WELDING ELECTRODESfor manual arc welding,

deposition and chopping

Shipment from Moscow warehouse:by railway containers, cars, self-exportation.

Customs registration.

Address: Volgogradsky prospect 41, Moscow, 109316, RussiaTel.: +7 (095)177-0038, +7 (095)177-0110, fax: +7 (095) 177-0284

E-mail: market@melon.ru; WWW: http://www.melon.ru

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The brochure contains information on JSC «SpetsElectrode’s» employees’ reports at scientific and practical seminar, which took place in St.-Petersburg in May, 2000.

The brochure introduces the practice of today’s working experience of the largest electrode company of CIS countries and is designed for welding specialists.

The composers:Polischuk G.N., Oreshkina E.V., Mikheeva E.N., Afanasenko A.E.,

Dudkin V.P., Dr. Mazel Yu.A., Dr. Shelepov E.P., Manevich N.M., General edition - Dr. Kuskov Yu.V.

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CONTENTS

JSC «SpetsElectrode».....................................................................................4

Dr.Kuskov Yu.V., eng. Mikheeva E.N.Strategic planning of an electrode company ...................................................6

Eng. Afanasenko A.E.Analysis of the state of the CIS countries welding materials market ...............17

Eng. Karpenko O.V., Dr.Dudkin V.P.Role of proof-of-concept labs in the quality assurance ....................................21

Eng. Kiselev V.V., Dr.Dudkin V.P.Quality assurance in covered electrodes production in requirements of a holding company .............................................................................................23

Eng. Ivanovsky E.B.Some trends of the solution of the problem of high alloyed coated electrodes production supply with the corresponding wire ..............................28

Dr. Shelepov E.P.G-232 model furnace for heat treatment of welding electrodes .......................31

Dr. Kuskov Yu.V., eng. Polischuk G.N.Topicality of the problem of harmonization of national standards for welding electrodes for shielded metal arc welding with international standards ISO 2560; EN 499 and production certification ...............................40

Eng. Polischuk G.N.Problems of maintenance of welding electrode quality and the modern raw material market .........................................................................................48

Eng. Avdeyev A.N.Modern grinding and crushing complex development .....................................51

Eng. Polischuk G.N., eng. Ivanov B.B.Development of technology of wear resistant deposit for repairs of details of carriage rolling stock of underground ...............................................56

Dr. Mazel Yu.A., Eng. Polischuk G.N.Covered nickel-base electrodes and area of their application.........................59

Eng. Dvoretsky G.V.Reconstruction of machine-building production at «JSC SpetsElectrode»...............................................................................................69

The appendix. Catalogue of electrodes manufactured by «JSC SpetsElectrode»...............................................................................................71

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JSC "SPETSELECTRODE"

Joint-stock company "SpetsElectrode" is a young quickly growing Russian enterprise manufacturing welding electrodes of special purposes.Despite of its young age, the company is a successor of centuries-old traditions of the school of remarkable Russian engineers of electrowelding metals N.N.Benardos and N.G.Slavyanov. "SpetsElectrode" has more than half a century experience of technological traditions of the Moscow experimental welding plant (MEWP) and continues the business of known in the electrode world of Russia and CIS countries N.D. Bykov - the MEWP director in 1944 - 1973, winners of the State premium: E.V. Sokolov, A.D. Rahmanov, N.A. Tarkhov. The company staff is generated from the workers of the Moscow experimental welding plant, "Geopribortsvetmet" plant, Moscow electrode plant, Ordgonikidze plant in Podolsk, experimental plant of CNIIChermet (Central Scientific Research Institute of black metals) institute of black metallurgy, Teploproject VNIPI (All-Russian Project Scientific Research Institute) , Promstalconstruction NIPI (Project Scientific Research Institute), etc. The large group of chiefs and experts joined the company from the Military Industrial Complex, including from the air industry.

For the short period of time the large industrial potential was developed including creation of efficient labour staff, designing, manufacturing and mounting of the equipment. Now about one thousand five hundred people work at five factories of "SpetsElectrode" system. The installation of eleven electrode manufacturing lines is completed, five more lines are in a stage of blocks manufacturing, which will allow to considerably improve providing of clients with wide range of high-quality products and to completely satisfy the growing demand for "JSC SpetsElectrode" products.

"JSC SpetsElectrode" produces all range of electrodes for manual arc welding according to its time-tested time original formulas, and also all gang of electrode manufacturing equipment manufactured at a specialized "SpetsElectrode" mechanical assembling plant. Being a conclusive advantage for the consumers of JSC "SpetsElectrode" products, the high universality of the plant allows to acquire all gamma of electrodes produced under the stable know-how of a single manufacturer.

The highest quality level of the products produced by the plant is time-tested and affirmed by quality certificates of Russian and Ukrainian GOSTs, Lloyd Register (Great Britain), Maritime Register of Shipping tolerance, Gosatomnadzor certificate, Russian and Ukrainian Ministry of Health hygienic certificates. The plant is awarded with the honorary

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diploma of " the Moscow quality " program and the plant products and production lines are given the highest level of quality within the program framework . The plant is the customary participant of the largest Russian and international exhibitions and conferences, the series of its expositions is marked by the Honorary diplomas: Moscow (Russia) 1995, 1997, 1999, 2000; Kiev (Ukraine) 1996; Minsk (Byelorussia) 1997, 1999; Essen (Germany) 1997;St.-Petersburg (Russia) 1998, 1999, 2000; Singapore 1999; Istanbul (Turkey) 2000; Nizhniy Novgorod (Russia) 1999.

JSC "SpetsElectrode" products were used in reconstruction of the Cathedral of Christ the Savior, construction of the memorial complex on Poklonnaya mountain, erection of the monument to Peter I, construction of Luzhniki Central stadium capping and of Commercial Center in Manezhnaya Square. The products are consumed by the Business Management of the President of Russian Federation, the Bolshoi theatre, theaters of Lenin Komsomol and "Sovremennik", McDonalds' restaurants network, oil and gas, space-rocket, chemical and construction complex plants, power plants and atomic industry, motor industry, shipbuilding, the Ministry of Means of Communication - more than ten thousand constant consumers. Products of "SpetsElectrode" are exported to all CIS countries, to Czechia, Germany, Egypt, Israel, Mongolia, Iran, Cuba, Turkey, China etc. JSC "SpetsElectrode" products and manufacture are blessed by the Russian Orthodox church clerics, including "Optina Pustyn" and Troitse-Sergiev Laurel monasteries.

JSC "SpetsElectrode" takes an active part in the activity of the "Russian scientific & technical welding society".

This brochure contains the reports of JSC "SpetsElectrode" employees, made at the scientific and practical seminar in St.-Petersburg.

To purchase welding electrodes please contact us at:tel.: +7 (095) 177-0033, +7 (095) 177-0038, fax: +7 (095) 173-0284

Supply of technological equipment for welding electrodes manufacturing:

tel.: +7 (095) 173-7431

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Dr. Kuskov U.V.; engineer Mikheeva E.N.JSC «SpetsElectrode», Moscow

STRATEGIC PLANNING OF AN ELECTRODE COMPANY

THE ESSENCE, FUNCTIONS AND ADVANTAGES OF STRATEGIC PLANNING

The dynamic process of strategic planning of an electrode company is the factor which incorporates all managerial functions. Without application of strategic planning advantages organizations and individuals will lack legible means of estimation of the corporate enterprise purpose or direction. The strategic planning process provides the base for managing the company staff.

STRATEGIC PLANNING of an electrode company represents a number of managerial actions and decisions which will result in working out of specific strategies designed to help the company to reach its goals.

The term «strategy» generated from the Greek strategos, «the art of a general». The military origin of this term must not cause surprise as this very strategos let Alexander Makedonsky win the world.

STRATEGY is a detailed comprehensive all-up plan to provide the fulfillment of the company mission and goals.

A number of basic theses dealing with strategy must be realized and , which is more important, accepted by the top management. First of all, the strategy is mostly formed and worked out by the top management, but its realization assumes involvement of all levels of management.

The strategic plan should be worked out from the point of view of the whole electrode corporation perspective, but not of an individual one. The owner of an individual firm is free to combine personal plans with the company strategy. But in most companies with a wide stockholding (including JSC «SpetsElectrode») it is not possible.

Strategic plan should be substantiated by vast studies and facts. To compete in today's world of business, the company should constantly collect and analyze huge amount of information about the branch, the market, the competition and other factors.

The strategic plan provides the company with definiteness and individuality which allows it to engage definite types of employees not involving other workers. The plan opens the company perspective which becomes the guideline for its employees, attracts new people and helps to sell the products and services.

Finally, strategic plans should be worked out not only to remain complete during the long time but also to be flexible enough to be modified and re-

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oriented in case of necessity. The general strategic plan should be considered as a program guidelining the company activity within the long time period taking into account the fact that the disputed and constantly varying business and social situation makes constant updating foregone.

Some companies as well as individuals can reach some level of success without spending much time on formal planning. More than that, strategic planning itself does not guarantee success. Like a car with an excellent engine design will not move on low quality petrol, the company creating strategic plans may fail because of mistakes in organization, motivation and control. Nevertheless, formal planning may create a number of important and in most cases significant favorable factors for the company.

The modern speed of changing and increasing of knowledge is so great that strategic planning is considered the only means of formal foreseeing of the future problems and opportunities. It provides the top management with means of creating of a long-term plan. Strategic planning also provides the base for taking decisions. The knowledge of the company goal helps to specify the most acceptable actions. Formal planning minimizes the risk at acceptance of a solution. Taking substantiated and systematized planning solution the management minimizes the risk of acceptance of a wrong decision because of the erratic or doubtful information about the company abilities or the external situation. The planning, serving to form the established goals, helps to create the unity of the common goal inside the company.

Forming of the strategic plan is a thorough systematic preparation for the future (figure 1). While all managers conduct formal strategic planning to some extent, working out of the company general strategic plans is mainly the concern of the top management. The principals of medium and lowest links participate in this process by providing the corresponding information and feed-back.

THE COMPANY GOALSThe first and may be the most significant decision at planning should be

the choice of the company goals. As it was stressed above and will be marked further, the companies which due to their size need multilevel systems, also require a number of widely formulated goals as well as the more specific ones linked with general company goals.

The main general goal of a company - the clearly formulated reason of its existence - is marked as its mission. The goals are worked out to fulfill this mission.

THE SIGNIFICANCE OF THE MISSION. The significance a corresponding mission being formally expressed and effectively introduced to an electrode company employees, is impossible to exaggerate. The

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goals worked out on its base serve as criteria for the whole further process of making managerial decisions. If the principals are not aware of their company main goal, they will not have a logical starting point for the choice of the best alternative.

The mission describes in details the company status and provides direction and checkpoints for determination of goals and strategies at different company levels. The verbiage of the company mission should contain the following:

1. The company task from the point of view of its major services or products, its basic markets and technologies. In short, in which type of business is the company engaged?

2. Exterior medium in relation to the company, determining the company working principles.

3. The company culture. Which working climate exists inside the company? Which type of people are attracted by this climate?

Considering the company mission from the point of view of determination of the consumers’ basic needs and their effective satisfaction, the management creates the clients for future support of the company. Undertaking the mission of creating the clients the business will gain profit necessary for its survival unless the management is good enough during the fulfillment of the mission.

THE CHOICE OF THE MISSION. Some principals, including electrode companies, do not concern about the choice and formulation of their companies’ mission. Very often this mission seems obvious to them. If you ask a typical shallow business representative about his mission, the reply will probably be: «To gain profit, of course». But if you thoroughly think this question over, the mismatch of choosing the profit as the general mission becomes obvious, though it is, no doubt, a significant goal.

The profit is a completely interior problem of the company. As the company is an open system, it can finally survive only by satisfying some need outside itself. To gain profit necessary for its survival, the company must watch the medium in which it operates. Therefore the management seeks the general company goal namely in the medium. To choose the appropriate mission the management must answer two questions: «Who are our clients?» and «Which needs of our clients can we satisfy?» In this case the client will be any person using the results of the company activity.

Though the mission, by all means, is of great significance for the company, it is impossible to underrate the influence of the top management values and goals on an electrode company. Our values are formed by our experience, education and social - economic phone. Values, or the relative significance which we pay to things and

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phenomena, route and guide principals when they face the necessity of acceptance of extreme solutions.

The general company goals are formulated and established on the base of the general company mission and certain values and goals which guide the top management. To pay a true contribution to the company success, the goals must possess a number of characteristics.

First of all, the goals must be specific and measurable.Expressing the purposes in precise measurable forms the management

creates a legible basis for the counting of the subsequent solutions and estimation of an operation course. Principals of the medium link will have a checkpoint for the solution if they should put more effect to education and training of employees. Also it will be easier to determine whether the company is operating well enough to fulfill its goals. As we shall learn afterwards, it becomes important at performing of the control functions.

The specific forecasting time is another characteristic of effective goals. It is important to specifically determine not only what the company wishes to fulfill, but also in general when the result should be achieved. Typically the goals are long-term and short-term. According to Stainer the long-term goal has the forecasting time of approximately five years or sometimes more - for technically advanced companies. The short-term goal is mostly one of the company plans to be completed within a year. The intermediate term goals are to be completed within one to five years.

Long-term goals usually have rather wide frameworks. They are formulated by the company first of all. The intermediate term and short-term goals are worked out to support the long-term goals. Typically the closer is the forecasting time of a goal, the narrower are its frameworks.

The goal must be reachable to serve to increase the company effectiveness. Setting of a goal which exceed the company opportunities either due to insufficiency of resources, or because of the exterior factors, may lead to catastrophic consequences. The goals «are important motives of human behavior in companies because usually people wish to achieve the goals set for the company» If the goals are unreachable, the aiming of the employees to success will be interlocked, and their motivation will weaken.

The goals will become a significant part of the strategic management process only if the top management formulates them correctly, then effectively implements them, gives an appropriate information on them and stimulates their fulfillment within the whole company. The strategic management process will be successful to the extent to which the top management participates in formulation of the goals and to which these goals reflect the management values and the company realities.

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THE EXTERIOR MEDIUM EVALUATION AND ANALYSISAfter determination of its mission and goals the management should

begin the diagnostic stage of the strategic management process. The first step will be exploration of the exterior medium. The principals evaluate the exterior medium by three parameters:

1. To evaluate the changes which influence different aspects of the current strategy.

2. To determine the factors being dangerous for the company current strategy. The control of the competitors activity allows the management to be ready for potential threats.

3. To determine the factors providing more opportunities to reach the general company goals by updating of the plan.

THE EXTERIOR MEDIUM ANALYSIS is a process helping the developers of a strategic plan to take into account the exterior towards the company factors in order to determine the opportunities and threats for an electrode company.

The exterior medium analysis helps to receive important results. It gives the company time to forecast the opportunities, to make the plan in case of unforeseeable circumstances, to implement a system of early warning in case of probable threats and to work out strategies able to turn the former threats into any favorable opportunities.

From the point of view of these threats and opportunities, the role of the exterior medium analysis in the strategic management process is mainly in the answer for three specific questions:

1. What is the position of the company now?2. What should be the position of the company be in future according to

the top management’s point of view?3. What should the management do to move the company from its

current state to the position where the management would like to find it?

Threats and opportunities which the company faces can be usually marked out to seven spheres. They are: economics, politics, market, technology, competition, international status and social behavior.

ADMINISTRATIVE EXAMINATION OF THE COMPANY STRONG AND WEAK POINTS

The next problem which the management faces will be determination of whether an electrode company has interior forces to use exterior opportunities and revealing the interior weak points which may complicate the problems dealing with exterior threats. The process helping to diagnose interior problems is called the administrative examination.

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THE ADMINISTRATIVE EXAMINATION is a methodical evaluation of the company functional areas used to reveal its strategically strong and weak points.

MARKETING. At examination of the marketing function of an electrode company one should pay attention to seven general spheres for analysis and study.1. Fraction of the market and competitiveness. The desirable fraction of

the market in percentage to its total capacity is an essential purpose positioned and is checked by the top management. Despite the common opinion, there is no necessity to control the market or even to occupy the dominating position there to provide profitability.

2. Variety and quality of the products range. Many companies have a single or limited range of products or services, while the others actively implement tens and hundreds of products.

3. Market demographic statistics. Quite a complicated problem for the top management is presented by control of variations in the markets and in concern of consumers.

4. Market studies and developments. Another problem for the management is market studies and developments of new goods and markets. The competitive business medium requires studies and developments of new and better goods and services.

5. Before and after sale servicing of the clients. One of the weakest points of modern business is the servicing function. Effective and reliable servicing helps to sell more goods, it creates and saves the clients’ loyalty. A lot of companies have the opportunity to set high prices due to excellent customer servicing.

6. Effective sales, advertising and promotion of goods. Aggressive competent sales group may occur the most valuable property of the company. In the same way, creatively directed advertising and promotion of products serve good complement to the products range.

7. Profits. The best goods or stimulating efforts will be worth practically nothing if they do not bring profit. Constant control of profit from various goods and services is an important control lever at the marketing function analysis.

FINANCE/BOOK KEEPING. The financial status analysis may be useful for the company and help to increase the effectiveness of the strategic planning process. There are numerous statements «in favor» and «against» the company financial revision. But in general the advantages of permanent control of the company financial situation, forces and opportunities considerable overbalance drawbacks and difficulties.

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OPERATIONS. It is rather important for the long-term survival of the company to constantly analyze the operations management (manufacturing in narrow sense).

HUMAN RESOURCES. The sources of the majority of problems finally may be found in people. There is a number of questions to be taken into account at examination of strong and weak points of the human resources function of any company (figure 2).

By thorough consideration of these questions the management can reveal potential weak points and undertake corresponding corrective measures. What can happen if the management ignores one or more of these questions?

If the company has skilled employees and principals with strongly motivated goals, they are able to follow various alternative strategies. Otherwise it is necessary to improve work because this weakness will most probably cause danger for the future activity of the company.

THE COMPANY CULTURE AND IMAGE. Finally we can mark out a restricted number of other factors which are direct responsibility of the top management. They cover important questions to be considered by the management in order to save normal interior and exterior state of the company. These non-traditional factors appear to play the decisive role in the successful operation of the company in the long-term outlook. They incorporate the corporate culture and image. The climate and atmosphere in the company are called corporate culture. Culture reflects dominating customs, traditions and expectations in the company. The management uses this culture for attracting of certain types of employees and for stimulation of particular types of population. Corporate image both inside and outside the company is related with the impression created by its employees, clients and common opinion in general. This impression stimulates the clients to buy goods from particular companies, but not from other ones. For instance, image may attract students to particular colleges and universities, but not the others.

The company culture and image are strengthened or weakened by the company reputation. Does the company have a good reputation in achieving of its goals? Was it consecutive in its activity? Which place does this company occupy as compared to other companies in this sphere? Does it attract good people? The answers to these questions will show whether the company culture and image are successful.After conducting of interior examination, revealing of strong and weak points and evaluation of factors on the extent of relevance, the management can determine the areas requiring immediate attention and those which they can rely on to use the opportunities in the exterior medium. After bringing interior forces and weak points to conformity with

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exterior threats and opportunities, the management can select the applicable strategic alternative.

EXAMINATION OF STRATEGIC ALTERNATIVESStrategic alternatives. The company faces four basic strategic alternatives. Limited growth is a strategic alternative which is followed by most companies. Limited growth strategy is characterized by establishment of purposes from achieved, corrected with allowance for inflation. Limited growth strategy is applied in mature industries with static know-how when the company is generally satisfied by its state. Companies choose this alternative because it is the easiest, the most convenient and the least risky method of operating. Typically the management does not appreciate variations. If the company was profitable in the past following the limited growth strategy, most probably it will continue following this strategy. The strategy of growth is conducted by annual significant increase of short-term and long-term goals level as compared to results of the previous year. The strategy of growth is the second most frequently selected alternatives. It is applied in dynamically developing branches with rapidly changing technologies. It may be followed by principals aspiring to diversification (a variety of products range) of their companies to leave the markets staying in stagnation. In a non-stable branch absence of growth may mean bankruptcy. In a static branch absence of growth or failure of diversification may lead to markets atrophy and absence of profit. Unfortunately, many companies prefer short-term growth getting long-term ruin in return. Growth may be interior and exterior. Interior growth may occur by expansion of products range. Exterior growth may occur in adjoining branches in a form of vertical or horizontal growth (for example, a manufacturer purchases a whole-sale company-supplier or one welding materials manufacturing company buys another one). Growth may lead to conglomerates, i.e. integration of companies in not bound branches. Nowadays the most obvious and recognized form of growth is confluence of corporations.REDUCTION. The alternative, which is the most seldom selected by principals and which is often called the last method strategy, is the reduction strategy. The level of the goals to achieve is set lower than in the past. Actually, for many companies reduction may mean a reasonable way of rationalization and re-orientation of operations. There may be several options within the frames of the alternative of reduction.1. Liquidation. This is the most radical option of reduction followed by

complete sales of the company material reserves and assets.13

2. Scissoring superfluous. Very often the companies consider it favorable to separate from themselves some divisions or types of activity.

3. Reduction and re-orientation. In conditions of a stagnant economy many companies consider it necessary to reduce part of their activity in attempt to increase profits.

Reduction strategies are most often applied when the company operating values keep on degrading at economic droop or just to save the company.

COMBINATION. The strategy of combining of all alternatives will be most probably followed by large companies actively operating in several branches. The strategy of combination is integration of any named above strategies - limited growth, growth and reduction.

Upon consideration of existing strategic alternatives, the management applies a specific strategy. The goal is to select a strategic alternative able to increase to maximum the long-term effectiveness of the company. Though selection of general strategy is both the right and obligation of the top management, the final choice will influence deeply the whole company. To make an effective strategic choice the top principals must have a legible, accepted by everyone concept of the company and its future. The strategic choice should be particular and have a single meaning. Adherence to a concrete choice often limits the future strategy, therefore the solution should be thoroughly studied and evaluated.

The strategic choice made by the management is influenced by various factors. Here are some of them:

1. The risk. Which level of risk does the management consider acceptable? The risk is a vital factor of the company, the high level of risk may ruin the company.

2. Knowledge of previous strategies. Very often consciously or unconsciously the management is influenced by previous strategic alternatives selected by the company.

3. Reacting to shareholders. Very often shareholders limit the management flexibility at selection of particular strategic alternative.

4. Time factor. Time factor may promote success or failure of the company at making a solution. Implementation of a good idea at the wrong moment may lead to ruin of the company.

The process of implementation dealing with application of long-term and tactic plans, procedures and rules, is rather complicated.

CONCLUSIONS1. Strategic planning is a process of selection of goals for an electrode

company and decision of what should be done to reach them.

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2. Strategic planning provides the base for all administrative solutions.3. Strategic plans should be worked out from the general company

positions, but not from individual ones. 4. There is a stable positive correlation between the formal planning and

the company success.5. The key components of the strategic planning are the goals,

instructions for acceptance of solutions and basic stages of the process of planning.

6. The first and probably the most decisive planning solution is selection of the company goals - its mission and particular objectives providing fulfillment of the mission.

7. The primary goal of the company is fulfillment of its mission, i.e. the sense of its existence. The mission should be officially formulated, and the company employees must be aware of it. The mission serves as the checkpoint on which the principals ground their solutions. Selection of too specific goal may narrow opportunities of the management at taking the decisions. The choice of too vast mission may affect the company success.

8. The goals must be particular and measurable, time-oriented, long-term or short-term, reachable and mutually supporting.

9. The link between the values followed by the top management and general company goals is of great significance. The management values appear in the company goals.

10. The exterior medium analysis is a process by which the management evaluates variations in the exterior medium and studies exterior opportunities and treats able to help or complicate achievement of the company goals.

11. The management should determine interior strong and weak points of the company to conduct planning effectively. Administrative examination is a methodical evaluation of the company functional areas.

12. The company has at its disposal four strategic alternatives - limited growth, growth, reduction and combination of these options.

13. The management selects a strategy upon the analysis of exterior opportunities and threats, interior strong and weak points and evaluation of all its alternatives and options.

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Figure 1. Formulation of «SpetsElectrode» system companies mission and goals.

1. How would you characterize the type of employees working nowadays in business and what will be required from them in future?

2. What can you say about the competence and skills of the top management?3. Do we have an effective and competitive system of bonuses?4. Have we planned the order of continuity of managing posts?5. Do we use effectively experience and improvement of professional skills of the

executives?6. Have we lost leading experts recently? If yes, then the reason of this.7. When did we last thoroughly analyze our system of the staff’s activity

evaluation?8. Can we improve the products and the work of employees by using the quality

groups and employees participation in the process of management.Figure 2. Some problems related to human resources

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JSC «SpetsElectrode» mission selection

1

Formulation of JSC «SpetsElectrode» goals

Long-term Intermediate-term Short-term3 3 4

Development of supporting plans (instructions for acceptance of solutions and actions)

Politics Strategy Procedures Rules Budgets 5 5 6 6 6

Development of supporting plans for each company of «SpetsElectrode» system

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(The figures show the approximate order of this process)

A.E. AfanasenkoJSC «SpetsElectrode»

ANALYSIS OF THE STATE OF THE CIS COUNTRIES WELDING MATERIALS MARKET

One of the electrode market features nowadays is inflationary processes taking place in the country at the present stage. While prices for raw materials and accessories necessary for electrode manufacturing constantly grow, the effective demand for electrode manufacturing products increases. At the same time significantly decreases the number of commercial intermediary companies which occupied their niche before by carrying out various sort of barter operations and lining of lengthy mutual payment chains. At this stage the major buyers are the final consumers of welding electrodes or some companies occupied with supply of particular productions included in the structure of a particular holding.

Therefore at this stage a basic factor for selection of a supplier for the consumers of welding materials becomes the quality of manufactured products. Here again rises the vital question of products certification and creation of quality systems under ISO 9000. All these question are successfully solved at JSC «SpetsElectrode». As you already know, our company permanently increases the manufacturing amount of electrodes of general use types МР-3М (MR-3M), ОЗС-41 (OZS-4I), OЗC-12, our company continues to develop intensively, every year we conduct wiring, triggering and yield on capacities of new electrode production lines. Typically at increasing of products manufacturing volumes it is necessary to increase sales volumes of welding electrodes and desirably this should happen before the production volumes growth. The high quality of products is verified by the certificates of Government standard of the Russian Federation, UkrCEPRO, Russian Maritime Register of Shipping, Gosatomnadzor of the Russian Federation, which allows the Marketing Department to solve the problems rather successfully.

The quality of manufactured products was checked in practice in comparison with electrodes by foreign manufacturers. It is a well-known fact that some types of JSC «SpetsElectrode’s» electrodes were approved by Lloyd Register (Great Britain). In November 1999 JSC «SpetsElectrode» delegation took part in «Essen Welding Asia 1999» exhibition which took place in Singapore where we presented our exposure. Upon conducting of welding works at our stand by JSC «SpetsElectrode» experts and also by welders of such well-known companies as ESAB; Messer; Kobelko it was practically established that

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some types of electrodes manufactured at our production facilities are no worse regarding the welding-technological properties than electrodes manufactured by the above mentioned companies. Besides, electrodes cost price and accordingly the products price at Russian manufacturers is significantly less than at the leading electrodes manufacturers which enables us to enter the international market of welding electrodes at the particular approach to the solution of this problem.

In 1999 JSC «SpetsElectrode» concluded a number of contracts for supply of electrodes to long-range foreign countries and performed this program successfully. In particular, a large batch of electrodes of general use was shipped to Peoples Republic of China for the construction of Lunungan atomic station which is conducted within the frames of interstate agreement between Russia and China; electrodes of general use were supplied to Egypt for the reconstruction of the largest metallurgical plant. The products were supplied to Czech, Poland, Mongolia, Vietnam and Iraq. Further we plan to increase sales volumes to long-range foreign countries while the basic market for sales of electrodes for us remains the Russian one.

Despite the after crisis economic growth, devaluation of the ruble and increase of sales volumes «for cash», the price factor continues to play a serious role in selection of a supplier. Even a very high quality of products requires a very serious approach to evaluation of the level of average prices for similar products. Typically the management of companies consuming the final products tries whenever possible to use more effectively the company money resources and to purchase electrodes at a lower price.

Reasonable combination of the products price and the quality of manufactured electrodes is vital for the successful realization of products. To decrease the products price, it is necessary first of all to learn to solve effectively the questions of decreasing the cost price of electrodes, which is rather successfully conducted in our company.

At present the tendency to magnification of demand for ordinary types of electrodes such as type МР-3 (MR-3); АНО-4 (ANO-4); ОЗС-4 (Э(Е)-46) and electrodes with the basic coating of type УОНИ (UONI)-13/45; УОНИ-13/55 is prolonged, and the decrease of demand for special types of electrodes, in particular for electrodes for welding of high alloyed stainless steels is prolonged. Here it is necessary to note that in connection with economic growth scored now in the domestic industry, the paces of dip of demand for stainless electrodes as compared to 1997 - 1999 have essentially decreased, however, to speak about any stabilizing of a particular level of effective demand for the composite types of welding electrodes is premature. At the same time JSC «SpetsElectrode» prolongs

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to carry out serial discharge of stainless electrodes in the amounts necessary for providing the market needs. The production growth at our plant takes place by increase of production volumes of electrodes of general use, and further increase of production volumes is supposed owing to types MР-3; МР-3M; ОЗС-4И (I) and others.

The situation at the market of electrodes in Russia and CIS countries in the beginning of 2000 is still characterized by existence of doubtful companies which often use registered bands of well-known manufacturers in their names and sell electrodes of doubtful quality as manufacturing plant’s products. For instance, a company named «Spetselectrode» operates in Volgodonsk, Rostov region, and in Yekaterinburgh. And the company in Yekaterinburgh while promoting electrodes to the market assured that they were our official dealers in the Ural region. Such companies sell electrodes of specific use at dumping prices which destabilize the market of electrodes. It is necessary to explain to potential consumers of electrodes that purchase of products from such «businessmen» does not guarantee at all the required consumer properties of an offered product.

The company’s activity in the sphere of advertising is of great importance for the product promotion. The way in which the potential consumer is informed of the goods, of its consumer qualities, of welding and technological properties of particular types of electrodes, of the price and the quality, means a lot. Advertising in press and specialized editions plays a great role. However, the main attention our company pays to specialized welding exhibitions which take place in our country and in short-range and long-range foreign countries as well. Exactly at the exhibitions the company has the opportunity to demonstrate its products to a great number of potential consumers and to establish the first working contacts which provide movement of our company’s products if the work is organized correctly.

JSC «SpetsElectrode» continues to use traditional methods of the products promotion to the market in its activity. But nowadays the new methods of advertising for our market appear. As it was said before, JSC «SpetsElectrode» has its Email address and Internet site. Email allows to deliver on time and without distortions information to final consumers within a few seconds and to work more effectively, than sending information by fax. Our Internet site is a splendid means of advertising and receiving of information by Internet users. The number of Internet users in our country is growing every year, and this method of advertising begins to yield substantial rebound.

Proceeding from the above-stated, we may conclude that increase of manufacturing of general use electrodes for welding carbonaceous and

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low alloyed steels is rather perspective provided that to sell them the manufacturing plant has a concept of its products promotion to the market, and it will utilize all modern means of advertising for this purpose.

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Engineer O.V.Karpenko, Dr. Dudkin V.P.JSC «SpetsElectrode»

ROLE of PROOF-OF-CONCEPT LABS in the QUALITY ASSURANCE

The increased competition in the market of electrode products dictates the plants - manufacturers the necessity of fabrication of high-quality competitive products. The latter, alongside with the debugged technological processes, includes reliability and veracity of input, intermediate and acceptance check and is an integral part of the quality assurance.

The successful solution of such tasks requires proof-of-concept labs provided with modern equipment and a highly skilled staff capable to run this equipment.

Such tasks can be solved by the labs of the holding company aggregated in a uniform Proof-of-concept Lab " Center of consumables tests" (PL «CCT»).

PL «CCT» incorporates the labs of analytical control, X-ray spectral analysis and mechanical tests. All complex of tests is carried out on a modern test equipment passing the annual checkout in ROSTEST-MOSCOW. Every year the analytical lab takes part in interlaboratory trials held by ZAO «Institute of Standard Models» (Yekaterinburgh) which confirms by certificate the quality of the lab operation.

PL «CCT» is authorized by Gosstandard of Russia on technical competence to carry out certification approval of shielded metal arc welding electrodes for welding and depositing of mild, low alloyed and high alloyed steels, welding of cast iron, non-ferrous metals and alloys and has the certificate of accreditation No ROSS RU.0001.22ChS17. The accreditation sphere of PL «CCT» is determination of technological parameters, welding and technological properties of electrodes and carrying out of chemical analysis, mechanical and metallographic test of all weld metal.

All types of tests on input control of wires and raw materials and acceptance tests of manufactured products are carried out by qualified employees of the analytical laboratory according to standard Russian GOST methods. Standard specimen and chemical reagents used at carrying out the analyses are timely freshened after expire of the time of their operation or storage.

The definition of carbon and sulfur content in materials and components is conducted with the use of the express - analyzer "Leco" CS-244, of

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nitrogen - with the use of the express-analyzer AN-7514. The use of this equipment allows to determine with a split-hair accuracy within several minutes the content of the above elements.

For operative quality analysis of arriving raw material, such as ferroalloys, ilmenite, rutile and for determination of chemical composition of a deposited metal X-ray diffraction units SRM-20M and SRM-25 are applied.

The checkout of mechanical properties of arriving wires and structural material and of deposited metal or welded joints received at acceptance tests of manufactured coated electrodes is executed by the physical tests lab. The test complex incorporates determination of tensile strength, yield strength, impact ductility, elongation, bending angle, Vickers, Brinnel and Rockwell hardness.

Recently PL «CCT» has carried out certification tests of coated welding electrodes on conformity to Russian GOST requirements for JSC «SpetsElectrode», JSC «Uralchimmontazh» on conformity to Russian Maritime Register of Shipping requirements, JSC «Lusinoostrovsky electrode plant», Carload depot of Paveletskaya railway, on conformity to UkrCEPRO (Ukraine), RF Gosatomnadzor requirements for JSC «SpetsElectrode».

Thus, proof-of concept labs are an important part in the quality assurance of a holding company aspiring to provide a rather high quality level of the manufactured shielded metal arc welding (SMAW) electrodes for welding and depositing.

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Engineer V.V.Kiselev, Dr. Dudkin V.P.JSC «SpetsElectrode»

QUALITY ASSURANCE of COVERED ELECTRODE PRODUCTION in REQUIREMENTS of a HOLDING COMPANY

Nowadays a holding company combines the following productions: covered electrode, metallurgic and machine-building. All productions are linked by a single goal - to provide manufacturing of competitive in the interior and exterior market electrode products.

The establishing now organization of production of boarded welding rods for manual electric arc welding in requirements of a holding company allows to considerably expand opportunities of implementation of the quality assurance system by its distribution to all manufacturing parts providing fabrication of electrodes beginning from raw material and materials and ending with machinery.

Implementation of such a system will allow to provide the quality control of all stages of manufacture linking them all together and to influence actively all aspects of quality control. First of all it concerns implementation of a single system of input control of materials used in various productions. It will by all means effect the increase of quality of the holding company’s final product - the electrodes, and the decrease of production costs. The effectiveness of the quality system control is achieved due to structuralization of divisions by excluding from them duplicating subdivisions (CZL, metrology) and to quality assurance based on uniform requirements to design-technological normative documentation.

The SMAW electrode production today is disposed on two platforms: the acceptance and storage of materials for electrodes manufacturing is massed on one of them. The grinding branch is situated on this platform supplying ready components to both platforms.

Metallurgic production under the order of electrode production provides manufacturing of various types of alloyed and high alloyed wire with a complete production cycle including melt and subsequent alteration. It is especially important for manufacturing of a large range of electrodes of special use.

The machine-building production manufactures various equipment for covered electrode production including the following sectors: fusion and chopping of wire on electrode rods, the grinding branch, preparation of a liquid silica glass, preparation of the coating, pressuring and heat treatment of electrodes, spare parts for blocks repair and the entire machinery and quickly wearing tools overhaul.

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Thus, proceeding from the goals, tasks, conditions and structure of a holding company the quality control structure was accordingly changed. Engineering control departments of each plant were integrated to Quality Assurance Department. It provided implementation of a single quality control system of all productions and coordination of all holding company divisions included in this system.

The quality assurance system of electrode production is regulated by a set of standard production procedures (SPP) of the plant designed according to the requirements of the international standards ISO 9000. SPP determines production links and mutual operation of structural divisions participating in organization of quality control and volumes, stages and content of the conducted control.

The direct participants of the process of the existing system assurance are the following departments: covered electrode production workshops, technical department, electrode quality assurance department, electrode testing lab, covered electrode welding test area, mechanical department manufacturing models of covered electrodes, PL «CCT».

Quality assurance of manufactured electrodes incorporates the following stages: input inspection of welding wire and electrode coatings components; inspection of components preparation for application; inspection of straightening and chopping of wire for electrode rods; inspection of covered electrodes manufacturing and conducting of their

acceptance test; inspection of packaging and storage of the finished products.

The input inspection of welding wire incorporates checking of certificates of fitness data, markings, surface quality and geometrical parameters for conformity to requirements of the contracts and the existing normative documents. The elective or close inspection of the arrived consignments on chemical composition and mechanical properties is conducted depending on the supplier and the wire trade mark.

All arriving components of electrode coatings are subject to input inspection which incorporates checkout of the marking, certificates of fitness data on the chemical composition, dampness, distribution of sizes and other parameters.

Volumes and methods of the input inspection is regulated by the holding company’s technological documentation.

Each particular case of non-conformity of the wire or the components to the normative documents requirements is examined engaging the supplier followed by acceptance of the final solution: either the material is not enabled in production and is reverted to the supplier, or material is enabled in production on a map of resolution on retreat from the normative

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documentation. The material enabled in production on a map of resolution is selected into a separate batch.

The inspection of the components preparation on operations of crushing, grinding, drying and sifting is carried out directly by the working staff and master of the grinding department. The quality of grinded components is checked by the controllers by the results of mesh analysis of distribution of sizes determined in the electrode lab.

The inspection of liquid silica glasses' properties prepared for making of crude coating mass, is carried out by electrode lab staff. The fidelity of dry components dosing process is checked by results of random inspection of a dry batter dosage mass.

Alloyed and high alloyed wire is subject to additional inspection on endorsement of brand composition at the stage of straightening and copping of wire for electrode rods. Such a staged inspection allows to exclude confusing the wire trade marks at simultaneous manufacturing of several trade marks of special-purpose coated electrodes.

The quality of electrode rods after the wire straightening and chopping is checked by limiting deflections of length and diameter, magnitude of burrs, bending deflection and undulation of rods and regulated by technological instructions and SPP.

The quality of electrodes pressuring is determined by eccentricity of deposition on rods. During the process of pressuring the press operator carries out fissile check of the this index. The solution on conformity of each batter to the requirements of the normative documentation on coating eccentricity is accepted by the controller by the results of measuring of this electrode index in representative sample of each batter.

Manufactured coated electrodes are reshaped on batches and diameters and are presented on acceptance tests waged in bulk of the requirements of technological rules, GOST 9466-75 and other normative documentation.

The electrodes sorting and packaging process is inspected by diameters, trade marks and batches according to the normative documentation requirements and terms of coated electrodes delivery to the customers.

The established system of input and operational inspection and acceptance tests allows to provide rather effectively the observity of production processes and electrodes identifying on diameters, trade marks and batches.

The important elements of the quality assurance system of coated electrodes production are: training of production and quality assurance department staff under

special programs;

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maintaining of technological fidelity of machinery by planned preventative repairs and routine examinations.

All research connected with determination of chemical composition and service properties of materials and manufactured products are conducted in PL «CCT» of MEWP which serves all productions within the holding company. PL «CCT» analytical lab annually takes part in interlaboratory tests on analysis of components in ciphered samples of black metallurgy materials. Based on the results of these tests, JSC «Institute of Standard Specimen» confirms the quality of the results of the analysis executed by the analytical lab and issues a certificate. PL «CCT» of MEWP is authrized by the Russian GOST and Maritime Register of Shipping.

Electrode trade marks manufactured by the holding company have certificates of fitness of Russian and Ukrainian GOST and hygienic certificates of the Russian Ministry of Health. A number of electrode trade marks are certified by Maritime Register of Shipping, Lloyd Register (Great Britain) and possess the «Moscow quality» Diploma certifying the high quality level of the manufactured products and Gosatomnadzor license.

On metallurgical production at manufacturing of alloyed wire the inspection of each operation is accepted at all stages of its manufacturing. Intended for fusion blend materials and components pass input check in a part of availability of the certificates of fitness, markings and checkouts of chemical composition on conformity to the requirements of the normative documentation.

Each fusion is checked by the chemical composition of fused steel brand. Upon fusion the state of all ingots’ surfaces readiness for further alteration is being checked.

Further operations on alteration of ingots into the wire of the required diameters are carried out under the technological instructions and are checked by metallurgy quality assurance department upon completion of each alteration. The manufactured wire is submitted to acceptance tests on diameters, fusion and trade marks on conformity to the requirements of the state normative documentation.

Products quality assurance of the machine-building production is based on similar principles. Input inspection of arriving materials and accessories incorporates checkout of availability of quality certificates for materials and passports for accessories, their completeness and marking. The exterior examination is carried out to reveal the surface defects. At the absence of quality certificates the materials are identified by their chemical composition and mechanical properties. The accessories are tested on work capacity.

At manufacturing of details the control of each operation is conducted according to technological route maps. Assembly units pass a preliminary

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operating time if it is stipulated by the technological and design documentation. The assembled products are exposed to acceptance tests. The purpose of these tests consists in checkout of the products’ work capacity and technical characteristics on conformity of passport data.

The machine-building products quality assurance system includes metrological expertise of the design documentation, metrological preparation of checkout, development of measuring and tests methods, technological preparation of production, metrological check of the gauging and handling tool, planning and preventive repairs of machine tools to maintain their technological fidelity, training of the staff.

Thus, a uniform system of manufactured coated electrode, metallurgical and machine-building products quality assurance in terms of a holding company allows to realize a number of relevant moments: to implement a uniform normative base for all productions; to decease the production costs connected with serving of the quality

assurance system; to initiate a uniform system of input inspection of arriving raw material

and materials; to implement a uniform quality assurance system conforming to the

principles of ISO 9000 system; to increase the quality of manufactured coated electrodes.

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Eng. E.B. Ivanovsky JSC «SpetsElectrode»

SOME TRENDS OF the SOLUTION of the PROBLEM of HIGH ALLOYED COATED ELECTRODES PRODUCTION SUPPLY

WITH the CORRESPONDING WIRE

During the last 10 years the demand for electrodes for welding of high alloyed steel and alloys has sufficiently decreased. The reasons are well-known, and their analysis is hardly of any interest. Nevertheless, the demand exists and, to say more, there is a tendency to its expansion. We mean first of all coated electrodes of АНЖР(ANZhR)-1, ANZhR-2, ЦТ(TsT)-28, ОЗЛ-17У(OZL-17U), КТИ-7А (KTI-7A), ОЗЛ-9A, ОЗЛ-25Б(OZL-25B), ОЗЛ-37-2, ЦНИИН(TsNIIN)-4 grades and some others.

Taking into account the price, the difficulty of manufacturing and financial opportunities of the customer, the volume of the orders for these grades usually varies from several packs up to 300 kg, in some cases, very rarely, it is a little bit more.

JSC «SpetsElectrode», possessing the equipment, labs, experts and corresponding experience based on more than half a century experience of Moscow Experimental Welding Plant, is ready to fulfill the orders for the above mentioned coated electrodes, however, in some cases it has to deny the clients or to slow down the terms of an order execution for uncertain time (usually for acquisition of a package for one grade from different customers to accumulate the money for purchase of the wire of the necessary trade mark, as the minimum amount of wire, which the corresponding manufacturer is ready to deliver is 60-1000 kg or more). At average cost of $ 10 for 1kg of the wire, in a number of cases its purchase in the amount of 1000 kg became problematic.

To solve the problem of stable supply of the necessary wire grades in the required amounts we addressed one of JSC «Supermetal» Holding plants which due to a number circumstances seemed to ideally fit to the solution of the set objective. During a long time period the plant specialized in melting of special alloys, had forge - press facilities, thermal equipment, pickling branch, drawing machinery, skilled staff. However, till a particular time it was able to produce no more than one ton of wire of one grade with terms of execution (from order till execution date) of three and more months.

The detailed investigation of the problem showed that the reasons of such a state were of both technical and organizational origin.

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Let us consider some technical problems we had to solve and which are being solved at present.

The production cycle of the wire manufacturing at JSC «Supermetal» consists of the following stages: blend preparation; melting of the required grade of metal; chemical analysis of metal; dressing of the defect layer; hot forging with several transitions to a square of the required section

(with dressing); dressing of the defect layer; receiving of G 3-6 mm semi finished wire; thermal treatment of semi finished wire and pickling of an oxidized

surface or scales; liming of semi finished wire before redrawing; redrawing of a semi finished wire into a wire of the necessary diameter

with both intermediate and final heat treatment and pickling; determination of mechanical properties of the wire; acceptance by TCD (Technical Control Department).JSC «Supermetal», founded on the base of TsNIIChermet Experimental

plant named after I.P. Bardin, was designed and constructed as an experimental plant of a Scientific Research Institute, its production areas were occupied with a lot of experimental and testing machines mostly not completely developed or failed to justify themselves. For hauling of the wire of the diameters in which "SpetsElectrode" was interested, there were only two pre-war construction single rolling mills of foreign manufacture (average output of 100 kg in shift per transition). The problem of the wire restringing was quickly solved by starting a ID ZS A-2500 trice-repeated rolling mill with output of 400-500 kg in shift per transition, and by designing, manufacturing and starting a wire liming and drying machine, which utilized a standard block from drying-tempering furnaces. The wire pickling became a narrow point. There occurred a need in more capacious alkalinous and acidic baths with the volume of 4 m3, and it was also realized.

One more problem was the heat treatment of the wire. The heat treatment being practiced at the plant, conducted in gas ovens by spools weighting 15-25 kg did not suit us mostly not by the output, but by strength properties.

The similar tensile strength indexes along the wire length were achieved with great difficulties, and we could not always enter the GOST "gates"

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from the first time. The option of the wire heat treatment " in thread " was selected.

The above and some other measures allowed to achieve the wire production level of 6-8 tons a month of the diameters from 3,0 to 5,0 mm of 08X25H60M10 (Wld.-ЭП(EP)-606), X25H40M7 (Wld.-ЭП-673), 06X15H60M15 (Wld.-ЭП-367), Wld.-01X23H28M3D3T (Wld.-ЭП-516), 30X15H335V3B3T (Wld.-ЭП-198), Wld.-НМЖМЦ(NMZhMTs), 03X25МДГБ(MDGB) (ЭП-978) grades and others.

However, the further possible and required growth of the wire production faced the most serious problem for us - receiving of semi finished wire from quadrate. At present this operation is carried out applying cooperation.

To solve the problem of supply of our own semi finished wire, we engaged VNIIMetmach (All-Russian Scientific Research Institute of Metallurgical Machine-Buiding), UGTU (State Department of Technical Management), JSC «Supermetal» and JSC «SpetsElectrode» experts. A special rolling mill «280» is designed and being manufactured. The mill is being developed on the base of existing at the plant equipment (revertive two-roll cage «600»), equipment manufactured at the «Holding» production base and some blocks are being purchased. As an intermediate group of «280» rolling mill, upgraded «200» rolling belt mills will be utilized. Starting of «280» rolling mill will allow to receive 6,5-8,0 mm semi finished wire in packets weighting from15 kg or more.

CONCLUSIONSThe development of a specialized wire production for coated electrodes

of elite grades allowed:1. To satisfy completely the needs of the most requiring and choosy

customers in acceptable time limits.2. To reduce slightly the labor input of special coated electrodes

manufacturing, providing the electrode production with wire, the quality by which, being within the GOST limits, better conforms the requirements of simplification of the technological process of electrodes manufacturing and provides achieving of technological properties of welding electrodes in complete conformity to GOST and Technical Specifications of all weld metal.

3. To conduct operative feed-back between the wire and electrodes productions and between the marketing services at long-term and intermediate-term planning of electrode manufacturing.

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Dr. E.P. ShelepovJSC «SpetsElectrode»

G-232 MODEL FURNACE FOR HEAT TREATMENTOF WELDING ELECTRODES

The model G-232 double tunnel kiln operating in JSC "SpetsElectrode's" electrode shop since 1977 is utilized for heat treatment of general use and special-purpose coated electrodes arriving to the furnace immediately after pressuring and stripping of ends and butts.

The analysis of the market demand in electrodes carried out at development of technical specification on engineering showed the necessity to use the furnace for manufacturing of all range (about 140 trade marks) of coated electrodes being produced at the plant. Taking this into account the following technical requirements served as checkpoints during the furnace development: universality both in the sense of heat treatment of welding electrodes

with all types of coatings and in the sense of production of coated electrodes with different standard sizes (diameters from 3 to 5 mm, lengths from 280 to 450 mm with lengths pitch of 10 mm);

collateral operation of the furnace with two OSZ-3 electrodes manufacturing presses with total capacity up to 14 tones per shift of 4 mm diameter welding electrodes;

exclusion from the technological cycle of the preliminary drying stage; assurance of the high quality of heat treatment including electrodes

with heavy-gauge coating by utilizing of weak continuous modes; flexibility of technological line allowing to conduct simultaneous heat

treatment of welding electrodes of different standard sizes and to quickly reset from one electrode trade mark to another.

The furnace type was selected based on formulated technical requirements. First of all we had to exclude from consideration traveling ovens because of their drawbacks (damage of coating at transfers, tempering in layer, small time of heat treatment estimated in tens of minutes). The marked drawbacks reveal particularly at manufacturing of welding electrodes with 4-5 mm diameter basic and heavy-gauge coating. Compartment furnaces are not suitable either for realization of the above technical requirements due to their low efficiency. Therefore, the tunnel kiln was taken as a base for development since it allows continuous heat treatment (several hours) at high efficiency (up to 14 tons per shift).

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The further precise definition of the furnace type was conducted inside the class of tunnel kilns. Thus, completely engine driven tunnel furnaces with many-shelved containers 1,2 also were excluded from viewing as not meeting the requirements of universality on electrodes length and pliability of flow diagram. Therefore a tunnel kiln with electrodes hauling on frames was recommended to development.

From all the variety of constructions the narrow metal frames were selected for utilizing because of their positive qualities: the possibility to place coated electrodes of different lengths and diameters on them; maximal exposure to air current; possibility of their usage in conjunction with loading-discharging machines. However, on such frames coated electrodes lay leaning by a side surface of coating. To prevent occurrence of dings on wet mild coating and to exclude electrodes sticking to frames, the working bearing areas of the frames should be covered with a 3-5 mm thick soft material able to absorb moisture from the coating, possessing low heat conductivity and heat resistance sufficient for operation in the furnace working space. Besides, the substrate should withstand abrading efforts, and the joint between the substrate and the frame - the shearing stress, occurring at removal of coated electrodes.

By the moment of engineering the developers knew only felt as a substrate material, the temperature restricted application of which has determined the application range of the furnace - the complete heat treatment of rutile and ilmenite coated electrodes and only drying of welding electrodes with base coating.

Thus, the furnace construction supposes separate drying and tempering of electrodes with base coating, which actually completely compounds with the features of technological process of special-purpose coated electrodes manufacturing. After the first stage of heat treatment - drying, 4-5 mm diameter special-purpose electrodes are placed to intermediate warehouse and laboratory tested. The selected coated electrodes are tempered and tested on conformity to general specifications (the parameters checked: length of stripped end and transition section; pores, dings and cracks on the coating surface; exposure of the rod; the coating hardness and thickness variations), and also the all weld metal chemical composition, welded seam metal mechanical properties and coated electrodes’ welding-technological properties are determined.

In case the quality of electrodes meet the presented requirements, they are routed to tempering. If some defects are discovered, the coating is removed and the expensive rods are returned for repetitive application. In a number of cases the removed coating is also used again. Testing of welding electrodes after drying is feasible because it is more difficult to remove the coating from dried and tempered defected electrodes, besides,

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the quality of rods after the coating removal becomes lower. It is impossible to reclaim tempered electrodes copper rods at all, as in the process of tempering the copper gets burnt and becomes so ductile that there is no possibility either to remove a coating from such a rod, nor to apply a new one on it.

The furnace is designed by a specialized company and manufactured and mounted by the forces of JSC «SpetsElectrode».

To reduce the dimensional length the furnace has tunnel construction (fig.1) with consecutive passing of the 1st and the 2nd tunnels by coated electrodes. Electrodes transition from the 1st to the 2nd tunnel is carried out utilizing a cross-cut dolly 3. The tunnels are equipped with four heating items 4,5,6 and 7, each having a vent machine 8, electric heater 9, injecting 10 and suction 11 cubs. Heat zones I and II are situated in the 1st

tunnel, and heat zones III and IV are situated in the 2nd tunnel. Each of heating items is equipped with automatic temperature control system. The law of continuous control is carried out by three-phase tiristor tension transducers.

The 1st tunnel, cross-cut dolly and the 2nd tunnel have drives for charge movement. The drives are electromechanical with a worm-screw couple. The tunnels drives are connected with fluid frames 15 equipped with single action meshes 16. The frames make step-by-step reciprocation movements. At the furnace exit a lifting - pulling down door 17 is mounted.

The furnace operates in the following way. The workers remove coated electrodes from the stripping machine conveyer and roll them on the frames in a single layer avoiding contact of electrodes with each other. As it was already marked, the bearing areas of the frames are covered with soft water absorbing material. Frames with electrodes are placed on the pallet 18 equipped with wheels 19. The pallet is placed on the shop dolly 20. By placing one frame over another the workers form a pile 21 step-by-step. After completion of a pile the dolly is taken to the furnace and joined to it by special clamps. Then the fluid frame 15 with meshes 16 moves the pallet together with the pile from the dolly and sets it on the furnace routing elements. Simultaneously with moving of the first pile, all piles placed in the 1st tunnel also move for one spacing and the last pile moves from the tunnel on a cross-cut dolly. By means of this dolly the pile moves to the 2nd

tunnel entrance and stops. After that the work is followed by the mechanism of the 2nd tunnel piles moving, i.e. drive 14 in conjunction with fluid frame and meshes. It moves the pile from the cross-cut dolly and places it in the 2nd tunnel. Simultaneously with it all piles in the 2nd tunnel move for one spacing in the direction opposite to that in the 1st tunnel. The last pile at the exit section of the 2nd tunnel in the process of this movement

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is transferred to pre-joined to the furnace unloading dolly 22. The mechanisms work in automatic mode.

After furnace heat treatment rutile and ilmenite electrodes are routed to the inspection, sorting and packaging section, and welding electrodes with base coating - to intermediate storage and further to tempering in another furnace.

Starting of the furnace was conducted in short time limits (within two-three days), however, finishing works carried out collaterally with operation prolonged for more than a year.

The following blocks were subject to finishing and development: the system of mechanisms automation (determination of basic and

blocking switches locations); drives of movement of piles in the 1st and the 2nd tunnels and the

cross-cut dolly (the initially manufactured drives had insufficient speed of movement);

bearing blocks of heating items (the project block turned to be not strong enough);

vent wheels (purchased wheels manufactured at a specialized plant were broken, therefore we started utilizing reinforced wheels of our own construction);

some areas of tunnels and routing elements (non-exactness of mounting led to pile falling down).

A sufficient scope of works was carried out to select a frame substrate. Felt utilized during the initial period of operation has undergone destruction within 2-3 months and crushed because of exposure to temperatures of 160-180C.

Heat resistant rubber, fiberglass fabric, mica based electroinsulating tape, wood planks and some types of a synthetic tape were used as a substrate material in tests. One of synthetic heat resistant tapes was selected by the results of tests.

Collaterally with this was conducted a research on determination of method of substrate securing to the frame. Several types of adhesives were tested, however, the method of mechanical securement was selected.

The conducted finishing works resulted in achieving the furnace parameters formulated above in specifications. Some drawbacks were also revealed, the basic one is necessity to unload the whole charge for repair and preventive maintenance of the mechanical part.

During the process of industrial operation there were conducted the furnace tests. Figure 2 shows the curves of drying and tempering of electrodes with 3 and 4 mm diameter rutile coating MR-3M. The temperature of the air submitted to zones was 60,90, 150 and 180C. The

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aggregate endurance of drying and tempering is 3,5 hours. The figure shows that electrodes in the bottom part of the pile have the shortest drying time, the longest drying time is in the middle of the pile, the top layers of coated electrodes have medium intensity of drying (table 1).

Table 1

Coating humidityElectrodes position at the pile

heightElectrodes coating humidity,%

3 mm 4 mmEnd of zone 2

top 5,7 7,5middle 6,2 9,0bottom 5,3 6,7

furnace exittop 0,5 0,5

middle 0,6 0,7bottom 0,4 0,4

The humidity variation after zone 2 is sufficient, it reaches 0,5% for 3mm diameter electrodes, and 1,1% for 4mm diameter electrodes. At the furnace exit it decreases to 0,2%.

Despite the unequal humidity of electrodes in a pile, all electrodes by the end of the process achieve the dampness value of 0,4-0,7% which is rather satisfactory as the normative dampness is 1%.

Figure 3 shows the curves of drying of 3 and 4 mm diameter electrodes with base coating UONI-13/55. The nature of humidity distribution is the same as in the previous case, but the humidity variation at the pile height is sufficiently less (7,5-7,2=0,3% in the middle of the furnace as compared to 9,0-6,7=2,3% in the previous case). It can be explained by different temperature level in the compared cases. At temperatures in zones of 40...90C and drying endurance of 2 hours 50 minutes the final coating dampness is 4,5-5,1%.

The more deep drying of electrodes with base coating (up to 1,9%) is achieved by increasing of temperature level up to 110C and the process endurance up to 4,5 hours (fig.4).

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Table 2

The furnace technical propertiesNo Ratings Value1 Length, m

dimensionalof thermal chamber

27,125,0

2 Width, mdimensionalof thermal chamber

3,12,3

3 Height, mdimensionalof thermal chamber

3,21,6

4 Set power, kVt 2955 Temperature, C 40-1906 Output on 4 mm electrodes

tons / shift up to 147 Lumpsum loading, tons up to 8,58 Electrodes diameter, mm 3...59 Electrodes length, mm 280...450

10 Heat treatment endurance, hr. 3...511 Number of piles

in one tunnelin the furnace

50100

12 Piles movement cycle, min. 1,8...3,013 Weight of 4 mm electrodes in a pile, kg 70...8014 Electric power consumption, kvt/hr./ton 135...14015 Thermal efficiency,% 40-42

CONCLUSIONSThe opened up model G-232 furnace during its operation showed both

positive sides: universality of manufactured electrodes at different standard sizes

(with diameters from 3 to 5 mm, lengths from 280 to 450 mm and spacing of 10 mm);

possibility of drying and tempering of electrodes with rutile coating and of continuous drying(without preliminary drying) of 3 to 5 mm diameter electrodes with base coating;

collateral operation of the furnace with two OSZ-3 electrodes manufacturing presses under the flexible scheme, i.e. at simultaneous manufacturing of electrodes of different standard sizes with a rather high efficiency (up to 14 tones per shift of 4 mm diameter welding electrodes);

36

providing of high quality of heat treatment owing to absence of transitions, smooth continuous temperature control, mild thermal humidity modes (temperature in zones is from 40 to 190C at multiple air re-circulation) with heat treatment (from 3 to 5 hours);

and negative sides: unloading of the whole charge for carrying out of regular preventive

maintenance of the mechanical part.

REFERENCES1. Isakov V.P., Kotov M.E. Production line for coated electrodes

manufacturing. A.S. USSR # 618229, st. 01.08.76, published 05.08.78, bul. #29.

2. Orenstein E.I., Shelepov E.P. The engine driven tunnel electric furnace for welding electrodes drying and tempering. In edition Engineering and construction of thermal aggregates (Minmontazhspetstroi of the USSR, Glavteplomontazh, VNIPITeploproject). A book of works, edition 50, p.155-165, M., 1979.

37

Fig.1. Diagram of G-232 Furnace

Fig.2. Curves of MR-3M coated elewctrodes drying and tempering

Fig.3. Curves of UONI-13/55 coated elewctrodes drying and tempering

38

Fig.4. Influence of time-temperature coditions on process of coated electrodes drying

39

Dr. U.V. Kuskov, Eng. G.N.Polishchuk «JSC SpetsElectrode»

TOPICALITY OF THE PROBLEM OF HARMONIZATION OF NATIONAL STANDARDS FOR WELDING ELECTRODES

FOR SHIELDED METAL ARC WELDING WITH INTERNATIONAL STANDARDS ISO 2560; EN 499 AND

PRODUCTION CERTIFICATION.

In view of economic instability spreading not only in Russia but also in other countries of the CIS a lot of new welding electrode manufacturers have appeared. They are small enterprises and firms. This kind of production for them is the only way to survive in the complex surroundings and also a means of making a quick profit. It has recently stimulated the appearance in the welding material market of a disturbing quantity of so called «modified» trade names of electrodes covered by cheap substitutes which are often not checked at all. The absence of precise technique, proper production equipment and even the very inspection system can’t help showing up in the quality. The production technical level doesn’t also meet market demands, although the low cost of production might be very tempting for the unscrupulous consumer. Owing to these reasons for a guard of their concerns the leading welding electrode manufacturers in Russia should undertake such measures, as voluntary certification of products in systems GOST R, UkrSEPRO, certification of products by the Russian Maritime register of Shipping, foreign certified companies Lloyd’s Register, TUV etc., certification of systems of quality under the standards ISO 9000 etc., in spite of the fact that all these operations require major financial expenditures. At the severe approach to a problem of certification it becomes the effective argument in security of quality and competitiveness of domestic production as compared with foreign one.

At holding certification the conformity of quality of manufactured production to the requirements of the national standards is a must. However for production export and exit on the foreign market it is necessary, that production also met the requirements of the international standards ISO, EN or the requirements of AWS.

Russian welding electrode manufactures as their peers from countries of CIS are guided by standards GOST 9466-75, GOST 9467-75, GOST 10051-75, GOST 10052-75 currently in force. A lot of time has passed from the moment of their issuing and making alterations (in 1988 and 1990). The necessity for improvement of electrode production technology, increase in competitiveness and production quality puts forward new

40

requirements which cannot be given by the national standards currently in force. Electrodes for welding of mild and low-alloyed structural steels are the majority of the electrode output, therefore basic attention is paid to problems with the standards of that type of production.

The classification of electrodes for welding of mild and low-alloyed structural steels is made according to GOST 9467-75 «Covered metal electrodes for manual arc welding of structural and heat-resisting steels. Types.» The first attempt of harmonising this document with international standard ISO 2560 was made when the former was introduced and domestic electrode properties and quality were compared with foreign ones, although GOST has a lot of deficiencies. Nevertheless international standard ISO 2560 has been in operation of IIW commissions for some years and has a new draft which is under discussion. Distinction in systems of qualification become apparent under the scrutiny of ISO 2560 draft. They became considerable. It is the first time conformity and distinction of domestic and foreign standardisation systems has been considered in detail [1]. We would like to mention here only the key distinctions between two international standards ISO 2560 and EN 499 and domestic GOST 9467-75.

For example, complex symbol system setting electrode properties and all-weld metal chemical composition in new standard ISO 2560.2-97 makes the standard rather complicated for the efficient use and index remembering. All electrodes in ISO 2560.2-97 are divided into two classes of strength E43 and E48. It isn’t harmonised with domestic standard GOST 9467 where electrodes are divided into 9 classes according to their strength and ductility properties. The combination of several properties by two-digit code doesn’t allow to spread these codes on other welding materials. One of the standard items regulates requirements to weld metal chemical composition, although the definition of chemical composition is not obligatory for large types of electrodes.

The European Committee on Normalisation (CEN) accepted a new standard EN 499 in May,1994. This new European standard has 3 official editions. They are English, German, French. It is considered to be a national standard in 18 European states. Unfortunately, Russian Gosstandart representatives and leading experts of electrode production don’t take part in the development of such international normative documents. Therefore these documents remain unknown to a wide part of experts. New standard EN 499 covers indispensable indexes when marking electrode properties and all-weld metal executed by them. This standard substitutes standard DIN 1913-1:1984-06 currently in force which as well as ISO 2560 was partially harmonised with domestic GOST 9467-75.

41

Indexes of minimum tensile strength having been utilised in standard DIN 1913-1 are substituted by indexes of minimum yield strength. Impact ductility is marked by only one symbol that is 47J for minimum value of impact energy. On putting the standard into operation the conformities to GOST 9467-75 were liquidated. The requirements to data indispensable for electrode code, for comparison of all-weld metal technological and mechanical properties, for electrode choice were essentially altered. Domestic standard GOST 9467 -75 doesn’t regulate requirements to minimum yield strength of all-weld metal. Therefore electrode types set on the base of minimum value of tensile strength according to GOST 9467-75 and codes according to new European standard EN 499 are not correlated with. Here is an example: in accordance with GOST 9467-75 domestic electrodes ОЗС-33 (OZS-33) and УОНИ-13/55 (UONI-13/55) are of the same trade name Э50А (E50A) but should be treated as different trade names E42 and E38 accordingly in EN 499 as they have different yield strength. Other example is electrodes УОНИ 13/55К (UONI 13/55K) (trade nameЭ46А (E46A)) and electrodes ТМУ-21У (TMU-21U) (trade nameЭ50А (E50A)) with similar yield strength which could be marked by the same code E38 according to standard EN 499. At the same time electrodes of trade names Э42 (E42) and Э42А (E42A) (GOST 9467) couldn’t be classified at all as standard EN 499 doesn’t stipulate electrodes with tensile strength less than 410 MPa (table 1).

Table 1Code indexes of all-weld metal mechanical properties according to

European standard EN 499

Electrode code

All-weld metal mechanical properties Temperature at minimum Charpy impact energy KCV

47JMinimal

yield strength

0.2

Minimal tensile

strengthB

Minimal elongation

5

Code indexes

C

MPa % Z without regulationE35 355 440-570 22 A +20E38 380 470-600 20 0 0E42 420 500-640 20 2 -20E46 460 530-680 20 3 -30E50 500 560-720 18 4 -40

5 -506 -60

42

There are no requirements to all-weld metal impact ductility determined on Menage sample at normal temperature (KCU) in contrast to GOST 9467-75. It is results received on Charpy samples (KCV) that are considered to be establishing. Domestic electrode manufacturers don’t carry out tests of all-weld metal where impact energy achieves 47J on Charpy samples (except for tests according to rules of the Russian Maritime registers of Shipping). These data practically couldn’t be found in publications and reference literature. While carrying out certified testing by foreign certified companies Lloyd’s Register, TUV etc. some manufactures have recently been starting to carry out tests determining impact ductility on Charpy samples. These tests are carried out incidentally on several lots and the results of them are not available for experts.

The yield strength data and data on determined on Charpy samples impact ductility at normal and low temperature doesn’t allow to compare domestic electrodes with their foreign analogues which are penetrating on our market. It also prevent us from executing standardisation in accordance with international norms.

As electrode manufacturers we realise the fact that national standards GOST 9466 and GOST 9467 currently in force need revising urgently. Production certification according to international norms and export are impossible without it.

Complex of operations with engaging of leading welders, experts from leading electrode enterprises, Gosstandard of Russia is indispensable. It should be aimed at revising of domestic standards with achieving of harmonisation with international standards ISO 2560, EN 499 etc.

Unification of data bank on serial lots of available electrodes of broad range is a must. Mathematical statistics helps to determine minimum yield strength value and temperature at which impact ductility of all-weld metal (KCV) equal to 47 J/cm2 is achieved.

A huge expenditures of time and energy are required for such operations. The public international organization «Association Electrode» undertook the role of coordinator of the operations under statistical data collecting and development of the offers for standard alterations. The workgroup created within the framework of the «Association» set out collecting offers and notes both from welding electrode manufacturers and from welding material consumers for preparation of new edition of standards GOST 9466, GOST 9467 and GOST 2246. More than 60 enterprises manufacturing and consuming welding electrodes were polled for the period from July, 1999 to December, 1999. Following the discussion of all offers arrived a draft of new edition of standard GOST 9466.2 got ready and discussed at the Council of «Association». GOST

43

9467 75 is still under consideration owing to a lot of disagreements among the experts.

Table 2Comparative tests for definition of impact ductility on the samples

with different form of notch at +20C№ Type of electrode Type

according to GOST 9467-

75

Impact ductility,J/cm2

Decreasing of impact ductility value,

%

KCU KCV

1 ОЗС-4 (OZS-4) Э46 (E46) 125 109.5 242 ОЗС-4И (OZS-4I) Э46 (E46) 112 95.6 283 МР-3М (MR-3M) Э46 (E46) 112 96.1 284 ОЗС-12 (OZS-12) Э46 (E46) 133 106 205 УОНИ-13/45 (UONI-13/45) Э42 (E42) 206 173 166 УОНИ-13/55К (UONI-13/55K) Э46А

(E46A)232 197 15

7 УОНИ-13/55 (UONI-13/55) Э50А (E50A)

216 208 16

8 ОЗС-33 (OZS-33) Э50А (E50A)

210 181 17

9 ТМУ-21У (TMU-21U) Э50А (E50A)

246 209 15

10 ОЗС-25 (OZS-25) Э50А (E50A)

237 201 15

Despite of existing difficulties and expenditures at our enterprise for two years we have been carrying out researchers into determination of weld metal minimum mechanical properties, impact ductility at normal and low temperature on Charpy samples with sharp notch (KCV) for serial manufactured electrodes from our spectrum. Parent material selected for joint is plates from steel Ст3сп, steel 20 and steel 16ГС, 09Г2С. All examined joints are equal in strength with parent metal. Statistical data processing was fulfilled simultaneously. Received at Moscow Experimental Welding Plant in the early 1970s data for serial manufactured and laboratory lots of electrodes for general purpose were also used for comparison. Additional tests on Charpy samples were carried out simultaneously with tests on Menage samples. They were aimed at determining the level of impact ductility decreasing received on different samples (KCU and KCV) at normal temperature, and minimum temperature at which impact ductility equal to 47J/cm could be achieved.

44

While carrying out acceptance tests for these purposes in accordance with the requirements of international standards butt joints were welded. For comparative tests of impact ductility on Menage and Charpy samples at normal temperature regular butt joints with impact samples notched from them were produced. The notch was executed under the following scheme:

- U-notch - 3 samples, along weld notch;- V-notch - 3 samples, along weld notch;- V-notch - 3 samples, cross-section notch.To quality of the samples produced rigid requirements specially to the

precision of execution of the notch were presented. The test results of all-weld metal impact ductility at normal temperature on different types of samples are introduced in table 2. These data also show the fact that the weld metal produced by electrodes with basic coating less suffers from sharp notch than the one produced by rutile covered electrodes. This fact could be explained by the high ductility of weld metal produced by electrodes with basic coating.

The fractured KCU and KCV samples welded by electrodes with basic coating (УОНИ 13/15 (UONI 13/55) is an example) had both pure mat surface and mat surfaces with small sites of crystalline pattern. The fracture nature of rutile covered samples (for example ОЗС-12 (OZS-12)) changed completely for Charpy samples, they acquired pure mat fracture instead of mat one. As it is believed that higher impact ductility corresponds with mat (filamentary) fracture, than the received test results quite coordinate with the nature of fracture. Determination of impact ductility values for samples with sharp cross-section notch was carrying out in the temperature interval from +20 to-40C. The notch was started from lower temperature -40C but after receiving understated results , temperature was raised (table 3). Down to test temperature the samples were chilled in the mixture of liquid nitrogen with ethanol. Comparing data received with the one of past years we would like to check the influence of butt joint welding technology and location of notch on test results, to find out the influence of the raw-material base for electrode coating that has changed for 30 years on weld metal mechanical properties.

Table 3Test results of impact ductility determination at low temperature for

electrodes of serial lots№ Trade name of electrodes Type

according to GOST

KCV, J/cm2

+20 0 -20 -40

1 МР-3 (MR-3) Э46 (E46) 128 83 58 -

45

2 МР-3М (MR-3M) Э46 (E46) 96 62 48 -3 ОЗС-12 (OZS-12) Э46 (E46) 132 98 64 -4 УОНИ-14/45 (UONI-14/45) Э42А

(E42A)184 186 106 52

5 УОНИ-13/55К (UONI-13/55K) Э46А (E46A)

193 128 92 60

6 УОНИ-13/55 (UONI-13/55) Э50А (E50A)

228 121 110 65

7 ОЗС-33 (OZS 12) Э50А (E50A)

205 156 94 56

As it was found out during the tests, welding technology doesn’t almost influence on the test results but define and alter weld metal structure. It is the form of notch determining fracture energy that influences essentially on test results at normal temperature. At the correct notching the location of it doesn’t noticeably influence on the result. In case there is a thermally unwrought layer the decreasing of test results on impact ductility is observed. When comparing received test results with the ones of past year lots differences both on mechanical properties of weld metal and on all-weld metal chemical composition were detected. Another fact that should be taken into consideration is that the particular stability of properties takes place both at change-over of the material and at change-over of the supplier of it. It basically confirms our policies to hold on to rigid requirements as in choice of suppliers and material quality. By the test results a classification of electrodes we manufacture were carried out in accordance with international norms (table 4). Minimum yield strength data were received with statistical data processing of acceptance tests for the last two years. The amount of lots in samples is 25 - minimum and 125 - maximum. These experimental work is carried our with spreading of the spectrum of electrodes controlled.

Table 4Experimental estimation of manufactured electrodes

in accordance with international norms№ Trade name of

electrodes

Min

imum

yie

ld

stre

ngth

, MP

a

Min

imum

te

nsile

st

reng

th, M

Pa

Elo

nga

tion,

%

Indexes according to standards

GOST 9466-75,

GOST9467-75

ISO 2560 EN 499

1 МР-3М (MP-3M) 380 450 24 E 430 R24 E433R24 E35ZR242 ОЗС-4И (OZS-4I) 375 461 26 E 430-AP24 E433AR24 E35ZR243 ОЗС-12 (OZS-12) 357 453 26 E 431 R12 E433R24 E35ZR24

46

4 УОНИ-13/45(UONI-13/45)

352 420 24 E 412(4) B20 E430B20 -

5 УОНИ-13/55(UONI-13/55)

381 493 25 Е 514 B20 E514B20 E38ZB22

6 ОЗС-33 (OZS-33) 427 550 27 Е 514 B24 E514B20 E42ZB247 ТМУ-21У

(TMU-21U)390 515 25 Е 513 B20 E513B20 E38ZB22

8 ОЗС-25 (OZS-25) 427 534 26 Е 515 B20 E515B20 E42ZB22

47

CONCLUSION1. The lack of harmonization of national standards GOST 9466-75 and

GOST 9467-75 with international standards ISO 2560 and EN 499 makes impossible the certification of domestic production in accordance with international norms.

2. The unification of efforts of the electrode manufactures is required to create data bank of the results of minimum yield strength determination and determination of temperature at which the value of impact energy equal to 47J is achieved for the range of welding electrodes manufactured in Russia and CIS.

3. The received test results of impact ductility on Charpy samples at +20C and at low temperatures have revealed that our electrodes are not inferior to foreign analogues in this characteristic but are sometimes even superior.

4. Essential influence of variation of groove shape, butt joint welding technology on the test result at normal temperature isn’t detected.

5. There is an essential influence of delivered material quality on stability of acceptance test results.

6. With the help of wide circle of electrode experts the draft of edition of the maiden standard - GOST 9466.2 was created. It is now handed for consideration and examination to Gosstandard of Russia. The second standard - GOST 9467-75 is still under consideration.

LITERATURE1. Zaks I.A. Electrodes for welding of steel and nickel alloys. S.P.:JSC

Arktest, 1996, 381.2. Standart DIN EN 499 «Covered electrode for manual arc welding of

non-alloyed and fine-grained steels. Classification.» German edition, 1994.

3. GOST 9467-75 «Covered metal electrodes for manual arc welding of structural and heat-resisting steels. Types.»

4. Standard ISO/DIS 2560.2, 1997 - changed edition, draft.5. Catalogue JSC Spetselectrode «Electrodes for arc welding, all-weld

metal and notching».

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Eng. G.N. Polishchuk«JSC SpetsElectode»

PROBLEMS OF MAINTENANCE OF WELDING ELECTRODE QUALITY AND THE MODERN RAW MATERIAL MARKET

The problem of raw material market has emerged since the break-up of the USSR. The former raw-material base had been headed for rich and well-explored deposits of Ukraine, Georgia, Russia. Ties of many years’ standing between raw material suppliers and manufacturers happened to be broken off. The appearance of borders between the CIS countries complicated the delivery of materials and the price of them rocketed.

For instance, Ukraine, being a monopolist in rutile and ilmenite concentrate delivery, raised prices of the concentrates higher than the world prices. That applies to ferroalloy of Nickopolskiy and Zaporozhskiy Plants. To receive nowadays ferroalloys from Georgia, one has to overcome two borders. All these problems make Russian welding electrode manufacturers look for a substitute for imported materials and widely use Russian raw material.

However, the majority of raw-material suppliers don’t work straight to welding electrode manufacturers but resort to intermediate services. It sometimes happens to be difficult to find out the real origin of the material, as instead of documents of quality the intermediary grants only the writing out of the certificate without indications of the supplier. This fact can’t help showing up in the quality of manufactured electrodes.

In pursuit of low cost of production enterprises, especially small ones, substitute materials in short supply for cheaper and available, to the detriment of production quality.

The rigorous input and standard monitoring of the materials allows to reveal both positive and negative properties of new materials, the most accountable suppliers. Only after thorough inspection the new materials are accepted for production and included into the list of manufactured materials. We have been conducting such operations on samples represented both the exploration crews and the organizations developing new deposits. Probably therefore we experienced a raw deficit to a lesser degree than other enterprises.

But it would be desirable to stay on problems bothered all manufactures, both large and small-sized. It is range and quality of basic raw material offered by the domestic market. First of all the intense situation with manganese-containing raw material - that is mild ferromanganese, ferrosilicomanganese - should be mentioned. This raw

49

material isn’t fabricated by Russian ferroalloy plants, except for high-carbon ferromanganese which is produced by Kosogorskiy and Alopaevskiy Metallurgical Plants. Kluchevskoy Ferroalloy Plant, Novokuznetskiy Plant of Ferroalloys produced different alloys for iron and steel industry but they don’t keep welding electrode manufacturers in mind. As a rule, ferroalloys delivered from Ukraine by intermediaries are not of good quality. Only for half of the year 60 tons of mid-carbon ferromanganese ФМн88 and more than 25 tons of ferrosilicomanganese have been rejected as defective. The main claims are slagging and overflow of sulfur and phosphorous content in alloys in 2-2.5 times above the norm. Mid-carbon ferromanganese and ferrochrome of group «B» with a high phosphorous content are offered, while group «A» costs rather high of isn’t produced at all. Other ferroalloys such as ferroniobium and ferrovanadium are offered with aberrations on harmful admixtures.

Ferrotitanium and boron-containing ferroalloys are in great demand. The only manufacturer of them is Novolipetskiy Metallurgical Plant which fails in a stable operations.

In addition to materials of coating, the welding wire is known to be indispensable for electrode production and all electrode enterprises face the problems of it. Metallurgical and hardware factories, delivering a welding wire for electrodes for general purpose, have stopped the production of it at present and occupied in export deliveries of metal or have sharply reduced the volumes of the production. But it’s a common knowledge that 90% of all manufactured and consumed electrodes are electrodes for general purpose for welding of mild, low-alloyed, alloyed structural steels.

Nowadays the cost of welding electrode is determined by the cost of the core wire which grow every hour. Both the raw material quality and the one of welding wire of trade names Св-08, Св-08А aggravated noticeably. For different reasons more than 220 tons of wire were rejected as defective for the last half of the year. The main defects are geometry imperfection, aberration in chemical composition and surface quality, for example scores, lamination, wire-edges, rust. As far as high-alloyed wire is concerned problems here are much more severe. The quality of electrode with special demands for welding of high-alloyed steels and alloys in large measure depends of wire quality. And the prices of both the wire and these electrodes are rather high. Not each enterprise can afford a 100% payment in advance for the production.

From the variety of high-alloyed wire suppliers Beloretskiy and Izhevskiy Metallurgical Plants, Metallurgical Plant in Electrostal are worth mentioning. The quality of their production always conforms to the requirements of normative documentation, however these enterprises fail

50

in a stable operations owing to the lack of raw material and other internal reasons. It should be added that production volumes dramatically decreased.

The wire quality of famous Moscow Plant «Serp and Molot» is subjected to censure. Leasing its floor spaces to firms that supply stainless steel or rendering service in smelting of metal the plant quality department doesn’t bear any responsibility for the quality of smelted metal as the raw material quality «isn’t their business». As a rule, quality certificates doesn’t correspond to the facts. The !00% incoming control at our enterprises allows to prevent the launch of defective wire into production. Trade names manufactured by «Serp and Molot» plant with the help of intermediary organizations proved the most problematic. These are Св-04Х19Н11М3 (Cv-04X19N11MZ), Св-07Х19Н10Б (Cv-07X19N10B), Св-10Х16Н25АМ6 (Cv-10X16N25AM6). There are aberrations of chemical composition of alloying elements such as chrome and nickel, a carbon, sulfur, phosphorous, nitrogen content. The quantity of rejected wire has been more than 10 tons. There are problems with surface quality of high-alloyed wire after etching, with geometry and mechanical characteristics. In this connection one of our divisions has set out manufacturing of high-alloyed welding wire against accepted orders. As a rule these are rare trade names of welding wire for heat-resistant and creep-resistant electrodes.

We would like to draw the attention of metallurgists to our problems as the quality of special electrodes depends on a wire quality at the rate of 60-70%.

The problem of raw material deficit might be solved and is partially solved through new types of raw material, development of new deposits, utilisation of chemical and metallurgical industry waste and mastering the new technology of production of domestic ferroalloys. But the problem of quality manufacturing of high-alloyed core wire, new types of economically alloyed core wires, wire of special alloys is still pending and the solving of it is handicapped by the whole complex of problems of metallurgical production. The problem of revision of the normative document upon welding wire GOST 2246-70 currently in force should be tackled immediately cause it is aimed at getting rigorously controlled quality indexes of manufactured wire and harmonisation the standard with the international norms.

51

A.N. Avdeev «JSC SpetsElectode»

MODERN GRINDING AND CRUSHING COMPLEX DEVELOPMENT

Problems and intensity of operation of the complexPerspectives of electrode production development are subject to scale

of applying of manual arc welding by covered electrodes and structure of welded metal. The manual arc welding is the general method of welding. A large specialised production is the only way to satisfy the necessity for electrodes of general and special purpose.

To ensure the wide and quality range of components of two electrode producing shops a grinding and milling complex is developed for the purpose of material manufacturing in the number of 20000-25000 tons annually.

Complex structure consists of sites and lines for handling material. Depending on necessity for some components an optimal quantity of equipment, its arrangement, a transportation of the material for handling and a delivery of it to the dosage sites are picked up. An organisation of working conditions in 3 shifts is carried out on the complex sites and lines.

Complex structure:I. Marble handling site

1. Drying aggregate2. Jaw crusher3. Ball grinder4. Shaker

II. Grinding site for ferroalloys and other materials1. Jaw crusher

III. Ferroalloy crushing site with high output1. Ball grinders of periodic operation. 2. Shakers

IV. Crushing site for non-ore materials1. Grinders of continuous operation

V. Ball loading ferroalloy crushing site for particular materials with low output.

1. Ball grinders with small diameter drum of periodic operation.

VI. Component drying and passivating site

52

1. Shakers2. Muffle furnace

VII. Sift site for bulk material 1. Shakers

VIII. Waste processing line1. Mixer2. Conveyor3. Vibrating drier4. Ball grinder5. Shakers

IX. Dosage site1. Containers for components2. Electronic weights3. Batch carrier

Material heat treatmentLumpy marble is dried with special container by warming it with hot

steam of air from drier «Marico». The output is 15 tons per shift. Granulated and powder material is dried in vibrating drier СВТ-05-953. The output is from 600 tons up to 1500 tons per shift depending on the material. Muffle furnace is used if necessary.

Large and medium material grinding At mounting grinders and crushers an equipment scheme with vertical

layout that saves floor space, decreases manual labor and time for transportation material has been used. Several jaw complexes ensure necessity for grinding of marble and other materials. A jaw complex of crusher of СМД (CMD) type gives 9 tons of ground material per shift.

Fine crushing

53

Plate batcher

Loading

Container with coarse fraction

Container for finished component

Shaker

Ball grinder

Scheme of grinding

At unit «Ribachevskiy» 2 tons of marble per shift and140kg of powdered fraction that cannot be used in production has been received. The equipment layout shown in the scheme raises unit output up to 4 tons of marble per shift without any losses, as coarse fraction is given again for grinding.

Grinders of continuous operation with vertical and horizontal equipment layout are used for ferroalloy grinding. Ball shakers situated in a row on the floor are intended for crushing of ferroalloy brought into the coating of electrode for special purpose in small amount. The output varies depending on ball loading. For example its is from 600kg to 1200kg for Fe and Ti.

The loading of ball grinders is carried out through loaders. Unloaded material goes to plate batcher and then to shaker. The output of two grinders is 3 tons per shift for Fe and Mn.

Non-ore materials are crushed at grinders of continuous operation. The output is from 400kg to 600kg per shift.

54

Loading

Plate batcher

Ball grinders of periodic operation with high output

Shaker

Scheme of equipment vertical layout

Material Initial activity, sm3/g

Temperature, C

Final activity, cm3

Ground ferrosilicon 12 760 1.5-2Ferrosilicomanganese 8-10 350 2-3Copper silicide 18 300 4-7Ferromanganese 7-8 350 1-2Metal manganese 7-8 350 2-3

Muffle furnacesMuffle furnaces are used both for heat treatment of bulk materials and

for passivating of ferroalloys interacting with water solutions of liquid silica glass that have alcalinous reaction.

The unit output which amounts from 400 kg to 1 ton per shift depends on design features of the furnace, a heat rate of it, time of material transportation.

Sift site for ground materialsDepending on the quantity of the sifting material vibrating shakers СВ

20-9 are used. The output of a shaker is from 2 to 4 tons per shift.

Waste processing lineBeing in operation, extruding and stripping machines left some unused

material for coating (waste). The waste is collected in containers and each electrode trade name has its own container. Then they are transported to a waste processing line, after the operation a definite quantity of treated

55

Mixer

Conveyor

Vibrating drier

Conveyor

Loading

Ball grinder

ShakersBatcher

Containers for finished product

material for coating subject to electrode diameter and trade name is added to batches.

Electrode quality is determined not only by the steel trade name and the coating composition. It is the correct preparation of powder components of coating that influences it in a great degree. Therefore roots of electrode quality are in grinding and crushing complex.

56

Eng. G.N. Polishchuk, Eng. B.B. Ivanov «JSC SpetsElectode»

DEVELOPMENT OF TECHNOLOGY OF WEAR RESISTANT DEPOSIT FOR REPAIRS OF DETAILS OF CARRIAGE ROLLING

STOCK OF UNDERGROUND

Owing to aggravated crisis the engineering readiness of a carriage rolling stock of underground is reduced sharply in view of the lack of indispensable quantity of spare parts and their high cost. This situation results in the growth of specific weight of restored parts, taking into consideration their smaller cost at practically equal, and quite often greater lifetime.

The numerous details of the carriage rolling stock of underground in maintenance are subject to a wear, scores and have to be excepted from maintenance or restored by depositing new layer instead of worn one.

Major percent of depositions is mechanised. It compounds 70% for repairs to carriage rolling stock, 54% - coaches and 60% - locomotives.

A manual arc depositing method by piece-electrode for restoring of details of carriage rolling stock is widely used. The analysis of different types of wear resistant electrodes for deposition has shown the fact that the choice of electrode for restoring is rather limited. First of all it is explained by properties of the parent metal, from which details of a carriage rolling stock are produced. As a rule it is high-manganese steel such as 110Г13Л, 35Л, 20Л, 20ГЛ, Steel 35, Steel 45.

The mentioned above steels are considered as ones with restricted weldability and for achivement a quality weld joint a preheating up to 350-400C is recommended at the welding.

When forks of the gimbal clutch manufactured from Steel 35 are restored at Moscow Plant of carriage rolling stock repairs of Underground, the following technology is used: the old worn deposit is removed from forks working surfaces by manual arc welding with electrodes of МР-3 (MR-3) trade mark, then the surface is processed by an abrasive tool to move the scale away and after that the three-bead deposit of a new working layer is manufactured by ЭН-60М (EN-60M) and ОЗН-6 (OZN-6) electrodes. The examination of the new layer is carried out by a magneticpowder method.

As a result the rejection of details (because of deposit cracks) is from 50% to 90%.

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Being interested in the problem, we decided to develop a technology of carrying out of restored deposit at the repairs of forks of the gimbal clutch.

The surface of detail to be removed is rather small and we consider the use of metal-arc cutting to be rational as both the deposit and the cutting are carried out by the same tool and from the same power supply.

However welding electrodes for cutting are not profitable to use. The fused metal is blown not such intensively as desired, the surface of cutting is off-standard and has cavities, the electrode consumption is rather huge and besides, the additional surface treatment grinding operation is required. Comparative hygienic performances are listed in the table.

Electrode trade name

Dust releaseManganese

content in dust,%Gross, g per 1kg

of burnt electrodes

Intensity, g/min

МР-3 (MR-3) 11.8 0.46 9.0АНР-2 (ANR-2) 15.9 1.34 10.2ОЗР-1 (OZR-1) 17.2 1.10 -ОЗР-2 (OZR-2) 17.5 1.25 -

Besides the conducted researches have shown, that while cutting of metal by welding electrodes, a carboned surface layer of metal with the depth up to 6 mm is formed on the detail, which cannot be removed completely even after the next surface treatment of a detail for the new deposit. After the new deposit and sometimes during the deposition it is in the deposit that strains originate resulting in the cracking of the deposit metal at the stage of cooling.

In the offered technique the removal of the old deposit is made with cutting electrodes of trade names ОЗР-1, ОЗР-2.

With the aim to receive quality weld joints from any mentioned above steels a preheating for removal of arising efforts is used.

At gouging by the carbon electrode sites with high carbon content (up to 1%) can be formed on the surface of cutting. In the sites tears and cracks going deep into of metal are often appeared. While welding again longitudinal and more often transversal cracks are appeared in the heat affected zone and welds.

When using ОЗС-2 (OZS-2)electrodes for removal of old deposit a carbon content in surface layer is not more 0.4% that is as in parent material. At Vikkers hardness test of surface layers of metal it was established that an increase of hardness of the surface layer in comparison with the parent metal is spread to 5-6mm depth for cutting by the carbon electrode, 2-3mm - for МР-3 electrodes and 1-2mm - for ОЗС-2

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electrodes. The cutting surface doesn’t carbon and slag and drippings could be easily removed after cutting by electrodes ОЗР-2 therefore, the additional surface treatment grinding operation is not required.

The detail, which is forks of the gimbal clutch, is manufactured from Steel35. Preheating is required for the deposition. The heating zone is to be spread not less than 50mm on both sides of deposit location. For carrying out deposition of fork the surface is rather small and we have suggested that operation of edge preparation should be eliminated and heat released at cutting of the defect (worn) sites by electrodes ОЗС-7М (OZS-7M) be used instead of preheating.

Our experiments have shown that the detail temperature is more than 150C if deposition is carried out immediately after cutting of worn layer on all 4 surfaces of the fork. The deposition was carried out in accordance with a scheme, not allowing detail overheating by electrode ОЗН-7М (OZN-7M), diameter 2mm, in two layers.

The followed examination by magneticpowder method revealed an absence of cracks for 80% of deposited details.

We believe that the developed technology of restoring deposition will allow to decrease considerably the rejects rate and could be widely used at restoring of similar details.

LITERATURE1. Davydov N.G. High-manganese steel. M.: Metallurgy,1997.2. Gutman L.M, Uzkiv Y.M. Technology of cutting of details by

electrode АНР-2// Mechanised welding. - 1976. - №6. - 52-55p.3. Gutman L.M, Pokladiy V.R. and others Units and detail repairs of

railway carriage rolling stock by mechanised welding// Mechanised welding. - 19991. - №11. - 51-55p.

4. Shapiro I.S., Vishnyakov V.U., Sidlin Z.A. Electrodes for arc cutting and their properties and dependencies on mass of coating factor// Welding production. - 1990. - №7. - 19-21p.

5. Mazel U.A., Kuskov U.V., Polishchuk G.N. Classification of iron-base alloys for restoring and hardening deposit.// Welding production. - 1999. - №4. - 35-38p.

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Dr. Mazel U.A., Eng. Polishchuk G.N.

COVERED NICKEL-BASE ELECTRODES AND AREA OF THEIR APPLICATION

(REVIEW)

Owing to high corrosion resistance, ductility at low temperatures and perfect efficiency in the broad spectrum of service temperatures, nickel-base alloys are widely used in industry. The necessity for creation of new welding materials compositions on the nickel base is aroused by appearance of new breed of weldable nickel alloys [1,3]. It is necessary to mention that in some cases for providing corrosion-resistant weld metal on the parent metal level, welding materials with higher alloy level in comparison with the parent metal are required. Some types of electrode for welding of nickel-base alloys are introduced in the article. For indeed: types EN... in accordance with draft of European standard ISO/TC 44/SC 3№392, 1997(9-th edition) and types AWS... in accordance with standard AWS A5.11-90 [1,2]. An approximate conformity of domestic nickel-base electrodes manufactured according to GOST 10052-75 or specification with the above-mentioned standards is shown in table 1.

The nickel alloys have recently been used in the world could be roughly divided into 4 major groups:

1 - solid solution-hardened alloys;2 - chemical combination-hardened alloys;3 - dispersionly hardening alloys;4 - casting alloys.

The group of nickel-base hardened solid solution could be divided into following subgroups:

Pure nickelIn Russia for welding of constructions from pure nickel of НП-2 (NP-2)

and НА-1 (NA-1) trade names, deposition of corrosion-resistant layers on carbonaceous and high-alloyed corrosion resistant steels and deposition of rust resistant layer on low-alloyed steels electrodes ОЗЛ-32 (OZL-32) are used (table 1).

It should be mentioned that pure nickel is used at the temperatures more than 315C which is caused by high resistance of graphitization. Pure nickel alloys are most widely used in production of equipment for caustic and reactionary roll output, at production of food-stuffs [3].

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Electrodes EN 2061 (ISO) or Eni-1(AWS) are used for welding of constructions from pure nickel, of nickel-clad steel layer, for deposition on steel and for welding of dissimilar materials.

Copper-nickel alloys of monel typeAlloy of monel type is perfect in corrosion resistance in sea or saline

water, chlorine solutions and alkalis. It should be mentioned that electrodes for welding of monel metal AWS ENiCu7 are also used for copper alloy welding.

Electrodes EN 4060 (ENiCu-7) and EN 4061 are used for welding of Ni-Cu alloys, deposition on steel and also for welding of Ni-Cu-clad steel layer.

Chrome-nickel alloysAlloys ХН78Т (XN78T), ХН70Ю (XN70U), ХН45Ю (XN45U) are

referred to this group. They have perfect corrosion resistance at calculated temperatures and high heat resistance. High heat resistance is predominantly achieved in domestic alloys by introduction not less than 20% of Cr [5].

Electrodes of ISO EN 6077 (ENiCr19Nb) classification are used for welding of Cr-Ni and Ni-Fe alloys, metals, which are different from other alloys of similar application as the former have rather high Cr content. The electrodes are also used for cladding, welding of dissimilar materials, welding of nickel alloys for cryogenic purpose.

Chrome-nickel-iron alloysCr-Ni-Fe alloys have creep, heat and carbon resistance at calculated

temperatures. They are often used for manufacturing of equipment operating in corrosive environment (Cl ions) at 550C because of high cracking resistance in conditions of corrosion under high tension.

Domestic electrodes of type Э-10Х20Н70Г2М2Б2В (E-10X20N70G2M2B2V) of trade name ОЗЛ-25Б (OZL-25B) [5] are used for welding of alloy ХН78Т (XN78T), dissimilar materials and cast iron. The electrode could be used for welding of constructions operating at the temperatures up to 980C, however they don’t meet the requirements to creep and heat resistance at the temperatures more than 820C.

Electrodes EN 8025 (ENiCr28Mo) and EN 8125 (ENiCr26Mo) are intended for welding of copper-alloyed Cr-Ni-Mo alloys. The electrodes are also used for deposition, the first layer then should be deposited by Fe-Cr-Ni alloy.

Electrodes EN 6062 (ENiCrFe-1) are used for welding of Ni-Cr-Fe alloys, of clad Ni-Cr-Fe alloy layer and for deposition on steel. The

61

electrodes can also be used for welding of dissimilar steel and for welding of alloys operating at the temperatures up to 980C.

Electrodes EN 6092 (ENiCrFe-2), according to GOST 10052-75 they are Э-10Х20Н70Г2М2Б2В, are used for welding of Ni-Fe-Cr and Ni-Cr-Fe alloys.

Electrodes EN6082 (ENiCrFe-3) are used for welding of Ni-Cr-Fe alloys, for example for welding of clad steel on the clad layer(Ni-Cr-Fe) side and also for deposition. The electrodes can also be used for welding of steel with nickel-base alloys. In accordance with [1] it is accepted that the temperature of maintenance of the constructions welded by electrodes EN6082 isn’t to be more than 480C. The electrodes ensure the highest hot-crack-resistance of weld for the class of electrodes.

The electrodes EEN6093 (ENiCrFe-4), EN 6095 are used for welding of 9% nickel steel and they ensure weld metal of higher hardness than electrodes EN 6092. The electrodes allow to weld with the alternating current that eliminates the effect of magnetic arc-blow.

Electrodes EN6152 ensure all-weld metal with higher chrome content than Ni-Cr-Fe electrodes. The use of electrodes for welding of high-chrom alloys on nickel base is enabled. They can also be used for deposition of facing corrosion-resistant layers on low-alloyed and rust-resistant steel and for dissimilar materials.

Electrodes EN6333 are used for welding of nickel-base alloys. The welds are good at resistance to oxidation, carbonization, sulphide saturation. The electrodes allow to work at the temperature up to 1000C.

Nickel-molybdenum alloysThese alloys contain 16 and 28% of Mo and slightly low quantity of Cr.

Alloys are welded well and intended for operations in corrosive atmosphere.

Electrodes EN 0665 (ENiMo-7) are used for welding of Ni-Mo alloys, clad Ni-Mo layer of steel and for welding of Ni-Mo alloys with steels and nickel-base alloys.

Nickel-chrome-molybdenum alloysThe alloys of the subgroup are mostly intended for operations in

corrosive conditions at room temperature, they also intended for operations in oxidizing atmosphere at calculated temperatures and minor pressure. In Russia electrodes ОЗЛ-21 [5] intended for welding of equipment from corrosion-resistant alloys ХН65МВ (XN65MV), ХН60МБ (XN60MB) and alloys similar to them operating in highly corrosive environment are produced.

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Electrodes EN6625 (ENiCrMo-3) are used for welding of Ni-Cr-Mo alloys and deposition of Ni-Cr-Mo alloy on steel.

Electrodes EN1276 (ENiCrMo-4), that are roughly correspond to Э-02Х20Н60М15В3 (E-02X20N60M15V3) type in accordance with GOST 10050-75, are used for welding of low-alloyed Ni-Mo alloys, for welding of clad low-alloyed Ni-Cr-Mo layer of clad steel and also for welding of low-alloyed Ni-Cr-Mo alloys with steels and other nickel-base alloys.

Electrodes EN6620 (ENiCrMo-6), are used for welding of 9% nickel steel, the welds have linear expansion factor similar to parent metal.

Electrodes EN 6452 (ENiCr19Mo15) and EN 6455 (ENiCrMo-7) are intended for welding of low-alloyed Ni-Cr-Mo alloys, for welding of clad low-alloyed Ni-Cr-Mo layer of clad steel and also for welding of low-alloyed Ni-Cr-Mo alloys with steels and nickel-base alloys.

Electrodes 6022 (ENiCrMo-10) and EN 6024 (ENiCr22Mo16) are used for welding of low-alloyed Ni-Cr-Mo alloys, for welding of clad low-alloyed Ni-Cr-Mo layer, for welding of low-alloyed Ni-Cr-Mo alloys with steel and other nickel-base alloys.

Electrodes EN 6985 (ENiCrMo-9) are used for welding of low-alloyed Ni-Cr-Mo alloys, for welding of clad low-alloyed Ni-Cr-Mo layer of clad steel, for welding of low-alloyed Ni-Cr-Mo alloys with steel and other nickel-base alloys.

Electrodes EN 6030 (ENiCrMo-11) are used for welding of low-alloyed Ni-Cr-Mo alloys, for welding of clad low-alloyed Ni-Cr-Mo layer of clad steel and also for welding of low-alloyed Ni-Cr-Mo alloys with steel and other nickel-base alloys.

Electrodes EN 6627 (ENiCrMo-12) are used for welding of Cr-Ni-Mo austenitic stainless steels with each other, for their welding with stainless duplex steel, Ni-Cr-Mo alloys and steels. The weld metal composition is adjusted for decreasing of weld penetration through parent material that is capable of reducing the corrosion-resistance.

Electrodes EN 6059 (ENiCrMo-13) are used for welding of low-alloyed Ni-Cr-Mo alloys, for welding of clad low-alloyed Ni-Cr-Mo layer of clad steel and also for welding of low-alloyed Ni-Cr-Mo alloys with steel and other nickel-base alloys.

Electrodes EN 6686 (ENiCrMo-14) are used for welding of low-alloyed Ni-Cr-Mo alloys, for welding of clad low-alloyed Ni-Cr-Mo layer of clad steel and also for welding of low-alloyed Ni-Cr-Mo alloys with steel and other nickel-base alloys.

Electrodes EN 6617 (ENiCrCoMo-1) are used for welding of Ni-Cr-Co-Mo alloys with each other, for their welding with steel and also for deposition. The electrodes can also be used for welding of dissimilar heat

63

and creep resistant steels and alloys operating up to the temperature of 1150C.

Owing to high solubility in a depressing quantity of metals, a wide range of nickel-base alloys is created. Nickel and copper are almost completely dissolved in each other. Iron and cobalt are perfectly dissolved in nickel. The solubility limit of chrome in nickel is 35-40%, molybdenum - 20% [3]. It is necessary to say that all above-mentioned elements assist in improvement on weldability of nickel-base alloys.

Alloying elementsThe influence of alloying elements on nickel-base alloy properties is

shown below:-Fe - reduction of cost price, heat resistance improvement;-Cr - hardening owing to solid solution, heat and corrosion resistance

improvement;-Mo, W - hardening owing to solid solution, pitting resistance

improvement;-Co - heat, creep and corrosion resistance improvement;-Cu - improvement in corrosion resistance in sea-water, in H2SO4

atmosphere;-Al,Ti - strength improvement owing to appearance of Y-phase;-C - minimum amount for preserving of high corrosion resistance,

controlled amount for creep resistance preservation. It should be mentioned that nickel-base electrodes are often used for cladding problem solution.

Basic directions of nickel-base electrode applying 1. Joints of matching (of the same type) materialsNickel alloys are good to be welded, however the term «of the same

type» is not always fair as for weldability improvement an additional alloying of weld is required. It is necessary to take into account that weld metal might become anode to parent metal because of difference of microstructure and probable segregation of alloying elements. In that case the additional alloying of weld ensures a formation of cathode area to parent metal and metallurgical compatibility of weld with thermal influence zone. At nickel alloy welding for exception of opportunity of the hot cracking formation, to which single-phase structures are not resistant, it is necessary to withstand correctly the heat input and interpass temperature at welding.

2. Dissimilar welded joints

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The choice of electrodes for joining of dissimilar metals has to be based on the understanding of influence of series of metallurgical factors. For indeed:

a) difference in liner expansion factors between weld and parent metal;

b) degree of penetration to parent material;c) possible variations in solid phase after long-lived

maintenance at high temperatures;d) data of weld metal solubility in parent metal,

metallurgical compatibility of weld and thermal influence zone which are used for selecting of weld material parameters. The latter ensure minimum edge penetration and therefore, satisfactory properties of weld joints.

The welding of nickel-base alloys could be carried out with a considerable degree of penetration through parent metal subject to the right choice of electrodes. At the process a formation of unfavourable phase and intermetallic compounds is eradicated and it make electrodes ideal for welding of dissimilar alloys. Cr-Ni welds are resistant to -phase formation, doesn’t require a definite amount of ferrite as are resistant to cracking and lowering of low temperatures resistance owing to considerable edge penetration. The liner expansion factor of nickel-chrome alloys is situated between factors of carbon and austenitic steels.

Basic variants of welding of dissimilar metals transitional joints between Cr-Mo alloys and high-

alloyed stainless steels in power engineering; ensuring of hardness and low temperature ductility

of 9% nickel cryogenic steels, for example AWS ENiCrMo-6; ensuring of strength balance and corrosion

resistance of tubes API X65 clad inside by alloy 825, for example AWS ENiCrMo12 and AWS ENiCrMo-7;

ensuring of corrosion resistance, high hardness and ductility of 6% Mo and duplex stainless steel, for example AWS ENiCrMo12 and AWS ENiCrMo-13;

creation (cladding) of surfaces with high maintenance properties. With the purpose of ensuring of corrosion resistance of surface layers nickel alloys should be deposited on carbon and low-alloyed steels. Materials, that contain a huge quantity of harmful admixtures such as P, S, Sn, B influencing on hot crack appearance, are not recommended to use for cladding.

65

The nickel-base material application is subject to a series of limitations:

the need of a branch of industry in rather expensive nickel-base welding materials;

some welding wires are complicated (not technologic) in manufacturing;

arc process gives a burning off and transition into slag of expensive alloying elements;

nickel-base alloys are completely austenitic and moreover they are extremely hot cracking sensitive. The cracking could be aroused by non-optimum choice of heat input, temperature between beads, weld profile and also excessive harmful admixture content.

As a rule, all-weld metal composition is corresponded to parent metal chemical composition but some distinctions can exist owing to the necessity of introduction into the weld some components that allow to meet the requirements:

electrodes are subject to requirements of national and international standards (GOST, AWS, DIN, ISO etc);

electrodes are to ensure special requirements, for example heat and creep resistance, corrosion resistance;

corresponding welding wire which can ensure optimal weld metal composition is to be produced;

electrodes are to guarantee high welding and technological properties: soft arcing, possibility of bath control, easy slag removal, formation of weld of favourable shape and appearance.

The operations of new generation creation of nickel-base electrodes with high welding and technological properties and auxiliary performances of welded joints have been carried out lately. Let’s consider types of coating that have recently found their application to nickel-based electrode manufacturing:

Basic type of coatingIt is a coating of classic slag system of steel producing, when

carbonates and fluorites specially CaCO3 and CaF2 are used (picture 1). Usually the sum of CaCO3 and CaF2 is more than 50% in an approximately equal proportion. However the system has recently been improved by introduction into the coating composition of small amount of rutile [1]. In practice the electrode with coating is considered to be a basic one with improved welding and technological properties.

66

The improvement of mechanical properties of basic type electrodes is achieved by:

a) decreasing of oxygen content in weld;b) removal from weld of such harmful admixtures as sulfur.The basic type coating ensures the receiving of well deoxydated welds

of more favourable shape (absence of concentrator of strengths such as undercuts and swells). It promotes the improvement of hot cracking resistance of welds.

Rutile type of coatingUsually slag system of rutile electrodes contains more than 50% of

rutile (TiO2) balanced in equal proportions by small amount of basic components, for example CaCO3 and CaF2 and alumosilicates (picture 2). It should be mentioned that rutile electrodes ensure two-dimensional profiles of welds and in combination with rather huge residual humidity of coating they increase the risk of hot and crater cracking formation.

The features of rutile covered electrodes are:a) stable jet transportation caused by high ionisation

properties of rutile;b) easiness of arc-striking and restriking;c) possibility of welding with the alternating current.

Rutile electrodes has shown themselves to advantage for welding in the down position, cladding and in cases when the flat bead is indispensable.

Acidic - rutile type of coatingElectrodes have properties similar with the ones of typical rutile

electrodes. However an amount of acidic component - that is alumosilicate - has increased almost twice (picture 3). The increase of alumosilicate in coating promotes an improvement of weld shape (profile) and humidity resistance of coating (1). However at welding by rutile-acid electrodes the monitoring for welding bath condition is hindered.

LITERATURE1. ISO/TS 44/SC 3№392 (CEN/TC 121/SC-3 №426). Specification for

nickel and cidkel alloy covered electrodes for shielded metal arc welding. Ninth draft, May 1997, 20p.

2. AWS A5.11-90 «Specification for nickel and nickel alloy welding electrodes for shielded arc welding», 49p.

3. A review of nickel-base welding consumables. P.Stubbington. 1998 WTIA 46-th Annual Conference (Australia, Perth),12p.

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4. GOST 10052-75 «Covered metal electrodes for shielded metal arc welding of high-alloyed steels with special properties», 13p.

5. JSC «Spetselectrode» . Consumables. Electrodes for shielded metal arc welding, deposition and cutting. Catalogue, Moscow, 1998, 209p.

Table 1Type according to GOST

10052-75Trade name Type

according to AWS A5.11-90

Type according to CEN/TS 121/SC-3

Э-10Х20Н70Г2М2Б2В(E-10X20N70G2M2B2V)

ОЗЛ-25Б (OZL-25B) ENiCrFe-2 EN6092

Э-02Х20Н60М15В3(E-02X20N60M15V3)

ОЗЛ-21 (OZL-21) ENiCrMo-4 EN0276

Э-08Х14Н65М15В4Г2(E-08X14N65M15V4G2)

Цт-28 (TSt-28) ENiCrMo-5 -

- ОЗЛ-32 (OZL-32) Eni-1 EN2061- В-56У (B-56U) ENiCu-7 EN4060

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69

E. Dvoretskiy G.V.«JSC SpetsElectrode»

RECONSTRUCTION OF MACHINE-BUILDING PRODUCTION AT «JSC SPETSELECTODE»

The formation of a holding company «JSC SpetsElectrode»historically has occurred on the basis of several industrial enterprises of the Moscow region.

Each of them had the repair and machine-building base. And originally this two enterprises, which were included in the holding company in due course, were of the only machine-building profile.

It is also fair to Geopribortsvetmet Plant having specialised earlier in manufacturing of the equipment for a rare-earth industry. It is the Plant that has served as an industrial core for creation of present «JSC Spetselectode».

While developing electrode production, we have kept at «JSC SpetsElectrode»mechanical assembly production and it gave us the possibility to run the output of the whole range of equipment electrodemanufacturing. It is the equipment that is installed nowadays and is operated on three electrode plants of «JSC SpetsElectrode»system.

However, the existing power of mechanical assembly shop at «JSC SpetsElectrode»has ceased to satisfy to rising rates of welding electrode production growth, therefore in September, 1999 we initiated a new project realisation, that is the creation of specialised machine-building production for manufacture of the equipment, tools and spare parts for all plants of the holding company on the basis of Perovskiy Plant.

The harmonious and professional operation of the experts, principals and workers has allowed in 2 months to master on the plant the manufacture of the fast outworn tool.

At the same time there was a structural reorganisation of the plant, concentration of a majority of machine tool park from other enterprises of the holding company, transition of principals, experts and workers of machine-building specialities to one site.

In November - December the collective of the plant participated in manufacture of separate pieces of the 3rd line for Spetselectrode - Kxrapunovo, when the maiden samples of the automatic machine for straightening and chopping and of the rod feeder were assembled, in January - February, 2000 the plant produced 50% of the equipment for the 4th line including multirun travelling oven, and in March - May realised the

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complete manufacture of the 5-th line for rutile and ilmenite electrode production of 600 tons per a month.

The overgrowth of production is combined with the hard work on engaging the personnel and introducing them into the production.

By the 1st of March 2 mechanical assembly shops, repair - building shop, services of the department of the Chief technologist, Chief mechanics and checking department were completed.

Nowadays at the plant a capable of working staff of workers and experts in an amount 250 persons is formed.

The carriage and mounting of the mechanic-treating equipment from all the territories of the company is carrying out.

There is a lot of things to be done but the achieved results allow to hope that in due period in summer of 2000 the plant will go out on full capacity that is several lines of electrode production annually.

CONCLUSIONThe creation of specialised machine-building plant within the framework

of the electrode holding allows:1. To reduce considerably manufacturing and

equipment installation expenses.2. To put into service the manufacturing of spare parts.3. To release the considerable industrial floor spaces

for the electrode productions development, which has been engaged by repair mechanical and machine-building subdivisions.

4. To solve a problem of transition to block repair of electrodemanufacturing equipment.

5. To increase productivity of available park of electrodemanufacturing equipment.

6. To reduce the cost price of production manufactured by the enterprises of the holding company.

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AppendixCatalogue of electrodes manufactured by «JSC SpetsElectrode»

A catalogue contains the information only about the basic trade names from of 140 manufactured ones. The information you need about the other welding electrodes you can receive applying to us to the address: 41, Volgogradskiy prospect, Moscow, 109316 or by phone +7 (095) 177-00-38, +7 (095) 177-00-51, +7 (095) 177-03-01, fax +7 (095) 173-02-84, E-mail: market@melon.ru; WWW: http://www.melon.ru

The data concerning materials and the area of their application, are intended for electrode consumers. The information about mechanical properties is given for all-weld metal according to the existing standards. In each case properties of the weld joint are determined by welded metal, welding position and conditions.

Conventional signs of current kinds alternative current=/+/ direct current of reverse polarity=/-/ direct current of direct polarity= direct current

Approved by the documentationR - GOST R Certificate US -UkrSEPRO CertificateMR -Maritime Register Certificate LR -Lloyd’s Register Certificate MQ -Marine Quality CertificateRR -River Register CertificateGAN-Gosatomnadzor LicenseAll production has hygienic certificate of Minzdrav of Russia

Convertional signs of welding position

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Overhead

Vertical upward

Fillet

Horizontal on a vertical flat

Flat downhand

Vertical downward

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Trade names of electrodes

Welding position

Kind of current

, mm

GOST or/and Specification, type

according to standard or all-weld metal

Purpose and area of application Approved by

1 2 3 4 5 6 7 8Electrodes for welding of mild, low-alloyed and alloyed steels

УОНИ-13/45(UONI-13/45) =/+/ 2...5 GOST 9466-75,

GOST 9467-75, Э42АWelding of main constructions from mild and low-alloyed steels, with high requirements on weld metal to ductility, impact ductility and stability and cracking at normal and low temperatures.

R, US, RR, GAN

ISO E434B20,DIN 4340B10,E35AB22H10

ОЗС-12(OZS-12) ~, =/+/ 2...5 GOST 9466-75,

GOST 9467-75, Specification14-4-782 – 76Э46

Welding of main constructions from mild steels with ultimate strength to tearing up to 450 MPa. They are specially suitable for welding of metallic structures in hard-to-reach places and static conduit joints, carrying out of welds of small extent and posting of tacks. Welding from domestic power supply set by electrodes of small diameter.

R, US, LR, MR, MQ RR

AWS 6013,ISO E432R21,DIN E4330R3,EN E38AR12

ОЗС-6(OZS-6) ~, =/+/ 3...5 GOST 9466-75,

GOST 9467-75, Э46Welding of main constructions from mild steels with ultimate strength to tearing up to 450 MPa when higher welding productivity in the downhand weld position is a must.

R, US, GAN AWS E6020,ISO E430RR12023,DIN 4300RR11120,EN 38ARR32

ОЗС-12И (OZS-12I), ОЗС-4И(OZS-4I)

~, =/+/ 3...5 GOST 9466-75,GOST 9467-75, Э46 (E46)

Welding of main constructions from mild steels with ultimate strength to tearing up to 450 MPa. They are suitable for welding of wet, rusty, badly purified from oxides and other contamination metal.

RR, GAN AWS E6012,ISO E433AR24,DIN E4330AR7

МР-3М(MR-3M) ~, = 3...5 GOST 9466-75,

GOST 9467-75, Specification 1272-102-36534674-98

Welding of constructions from mild steels with carbon content up to 0.25%.

R, US AWS E6012,ISO E433AR24,DIN E4330AR,EN 38AR12

УОНИ-13/55К(UONI-13/55K) =/+/ 3...5 GOST 9466-75,

GOST 9467-75, Э46А

Welding of main constructions from mild and low-alloyed steels, operating at reversal loads and

R, MR ISO E433B20H,DIN E4330B10H,EN 38AB22H10

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lower temperatures, for example in diesel industry.

УОНИ-13/55(UONI-13/55) =/+/ 2...5 GOST 9466-75,

GOST 9467-75, Э50А

Welding of main constructions from alloyed and low-alloyed steels with ultimate strength to tearing up to 450 Mpa when high ductility, impact ductility and cracking resistance at normal and low (to -40C) temperatures are required to weld metal.

R, US, LR, MR, MQ RR, GAN

AWS E7015,ISO E514B20,DIN E5140B10,EN E380B22H10

ОЗС-33(OZS-33) =/+/ 3...5 GOST 9466-75,

GOST 9467-75, Э50А

Welding of main constructions from alloyed and low-alloyed steels with ultimate strength to tearing up to 450 Mpa when high ductility, impact ductility and cracking resistance at normal and low (to -40C) temperatures are required to weld metal.

R AWS E7016,ISO E514B24,DIN E5140B10,EN E38AB12H10

НИАТ-5(NIAT-5) =/+/ 2...5 GOST 9466-75,

GOST 10052-75,Э-11Х15Н25М6АГ2

Welding of dissimilar steels 3-ХГСА (3-XGCA), 30ХГСНА (30XGCNA)

R, UC ISO E16.25.6B30,DIN E16.25.6B30

ЭА-395/9 =/+/ 3...5 GOST 9466-75, OST 5.9244-87,OST В5Р.9374-81, 08Х16Н26М6АГ2

Welding of main construction from high-strength alloyed steels. They used at the manufacture of the capacity, heat exchange, reactor equipment, at the constructions of marine courts, equipment for a food, textile industry etc.

R, UC, MR, GAN

ISO E16.25.6B20,DIN E16.25.6B20

ТМЛ-3У(TML-3U) =/+/ 3...5 GOST 9466-75,

GOST 9467-75, Э-09Х1МФ

Welding of heat resistant steels 12Х1МФ (12Х1МF), 15Х1М1Ф (15Х1М1F), 20ХМФЛ (20ХМFL), 15Х1М1ФЛ (15Х1М1FL) for mounting of pipelines operating at temperature up to 570C.

R, GAN AWS E8015-G,ISO E1CrMoVB20,DIN EKb,CrMoV120

ЦУ-5(TSU-5) =/+/ 2.5 GOST 9466-75,

GOST 9467-75, OST 24.948.01-90, Э50А

Welding of alloyed and low-alloyed steels, elements of heating surfaces of boilers, rooted welds of junctions of pipelines, operating at temperature up to 400C

R, UC, GAN AWS 7015,ISO E510B20,DIN E5130B10

75

ТМУ-21У(TMU-21) =/+/ 3...5 GOST 9466-75,

GOST 9467-75, Э50АWelding of junctions of pipelines and main constructions from mild and low-alloyed steels 15ГС (15GC), 16ГС (16GC), 09Г2С (09G2C),

R, UC, GAN AWS E7015,ISO E513B20,DIN E4300B10,EN E42AB22H10

ЦЛ-39(TSL-39) =/+/ 2.5 GOST 9466-75,

GOST 9467-75, Э-09Х1МФ

Welding of heat resistant steels 12Х1МФ (12Х1МF), 15Х1М1Ф (15Х1М1F), 12Х 2М Ф CP (12Х 2М F CR), operating at temperature up to 570C.

R, GAN AWS E7015-G,ISO ElCrMoVB20,DIN EKb,CrMoV120

Electrodes for welding of high-alloyed steelsОЗЛ-36

(OZL-36) =/+/ 3...5 GOST 9466-75, GOST 10052-75, Э-04Х20Н9

Welding of corrosion-resistant steels 08Х18Н10 (08Х18N10), 08Х18Н10Т (08Х18N10T)

R AWS 308-15,ISO E19.9LS20,DIN E19.9Ncrb20

ОЗЛ-8(OZL-8) =/+/ 2...5 GOST 9466-75,

GOST 10052-75, Э-07Х20Н9

Welding of steels 08Х18Н10 (08Х18N10), 12Х18Н9 (12Х18N9), 08Х18Н10Т (08Х18N10T) when resistance to grain-boundary corrosion of weld metal is not required. They are used for manufacture of capacity, reactor, column equipment for food, textile industry etc.

R, UC AWS E308-15,ISO E19.9B20,DIN E19.9B20

ЦЛ-11(TSL-11) =/+/ 2...5 GOST 9466-75,

GOST 10052-75, Э-08Х20Н9Г2Б

Welding of corrosive steels 12Х18Н10T (12Х18N10T), 08Х18Н12Т (08Х18N12T) when rigid requirements to grain-boundary corrosion resistance of welds are a must. They are widely used for equipment of food industry.

R, UC, LR, MQ

AWS E347-15,ISO E19.9NbB20,DIN Е19.9NbB20

ОЗЛ-7(OZL-7) =/+/ 2...5 GOST 9466-75,

GOST 10052-75, Э-08Х20Н9Г2Б

Welding of corrosive steels 12Х18Н10T (12Х18N10T), 08Х18Н12Т (08Х18N12T) when rigid requirements to grain-boundary corrosion resistance of welds are a must. They are widely used for equipment of food industry.

AWS E347-15,ISO E19.9NbB20,DIN E19.9NbB20

76

ЦТ-15(TST-15) =/+/ 2...5 GOST 9466-75,

GOST 10052-75, Э-08Х19Н10Г2Б

Welding of main constructions of steels Х19Н9Т-Л (Х19N9Т-L), Х20Н12Т-Л (Х20N12Т-L), Х16Н13Б (Х16N13B), 12Х18Н9Т (12Х18N9Т) at manufacture of capacity, heat exchange, reactor equipment, the equipment for food, textile industry, operating at temperature up to 650C when resistance to grain-boundary corrosion of weld metal is required.

R, UC AWS E347-15,ISO E19.9NbB20,DIN E19.9NbB20

ЭА-400/10У(EA-400/10U) =/+/ 2...5 GOST 9466-75,

OST 5.9244-87,OST 5Р.9370-81, 08Х18Н11М3Г2Ф

Welding of main constructions of steels type 10Х17Н13М2Т (10Х17N13М2Т), 08Х18Н10Т (08Х18N10Т) at manufacture of capacity, heat exchange, reactor equipment operating in hostile environment at temperature up to 350C.

R, US, LR, MR, MQ,

GAN

AWS E317-15,ISO E19.12.3B20,DIN E19.12.3B20

ЭА-400/10Т(EA-400/10T) =/+/ 2...5 GOST 9466-75,

OST 5.9244-87,OST 5Р.9370-81, 08Х18Н11М3Г2Ф

The same application R, US, GAN AWS E317-15,ISO E19.12.3B20,DIN E19.12.3B20

НЖ-13(NZH-13) =/+/ 3...5 GOST 9466-75,

GOST 10052-75, Э-09Х19Н10Г2М2Б

Welding of main equipment from 1-Х17Н13М2Т (1-Х17N13М2Т), 10Х17Н13М3Т (10Х17N13МZТ), 08Х21Н6М2Т (08Х21N6М2Т) and similar ones, operating at 350°С. They are used at manufacturing of capacity, heat exchange, reactor equipment, the equipment for food, textile industry etc.

R, US AWS E318-15,ISO E19.12.2NbB20,DIN E19.12.2.NbB20

ОЗЛ-17У(OZL-17U) =/+/ 3...4 GOST 9466-75,

Specification 14-4-715-76, 03Х23Н27М3Д3Г2Б

Welding of corrosive alloys 06ХН28МДТ (ЭИ 943) (06ХN28МDТ (EI 943)), 03ХН28МДТ (ЭП 561) (03ХN28МDТ (EP 561)) steel 03Х21Н21М4ГБ (ЗИ 35) (03Х21N21М4GB (ZI 35)) for sulphuric and phosphoric acids.

R, UC ISO E23.26.3Mn2Cu3NbRB20

77

ОЗЛ-37-2(OZL-37-2) =/+/ 3...4 GOST 9466-75,

Specification 14-4-1276-84, 03Х24Н26М3Д3Г2Б

Welding of corrosive alloys 06ХН28МДТ (ЭИ 943) (06ХN28МDТ (EI 943)), 03ХН28МДТ (ЭП 561) (03ХN28МDТ (EP 561)) steel 03Х21Н21М4ГБ (ЗИ 35) (03Х21N21М4GB (ZI 35)) for sulphuric and phosphoric acids.

ISO E25.27.4Mn2Cu3NbB20

ОЗЛ-6(OZL-6) =/+/ 3...5 GOST 9466-75,

GOST 10052-75, Э-10Х25Н13Г2

Welding of main equipment from steels 20Х23Н13 (20Х23N13), 20Х23Н18 (20Х23N18) operating in oxidizing atmospheres at temperature up to 1000C and also for welding of dissimilar steels. They are used for manufacture of different kind of equipment for chemical, power, food, textile and other branches of industry.

R, UC AWS E309-15,ISO E23.12B20,DIN 23.12B20

ОЗЛ-9А(OZL-9A) =/+/ 2.5..4 GOST 9466-75,

GOST 10052-75, Э-28Х24Н16Г6

Welding of heat resistant steel of 12Х25Н16ГАР (12Х25N16GАR), 45Х25Н20С2 (45Х25N20С2), Х18Н35С2 (Х18N35С2) trade name, operating in oxidizing atmospheres at temperature up to 1050C and in carboned atmosphere at temperature up to 1000C. They are used for manufacturing of main equipment in different branches of industry.

R ISO E2516MnS20,DIN E2516Mn6RB20

ЦТ-28(TST-28) =/+/ 3...4 GOST 9466-75,

GOST 10052-75, Specification 14-4-1415-87, Э-08Х14Н65М15В4Г2

Welding of corrosive heat resistant dissimilar alloys ХН78Т (Э 435) (ХN78Т (E 435)), ХТ70ВМЮТ (ЭИ 765) (ХТ70VМUТ (EI 765))

R AWS ENiCrMo-5,DIN EL-NiCr14Mo15W4Mn2

АНЖР-1(ANZHR-1) =/+/ 3...5 GOST 9466-75,

Specification 14-4-568-74, 80Х24Н60М10Г2

Welding of dissimilar steels (high-alloyed, heat resistant with low-alloyed, creep resistant) and also for welding of quenched steels at manufacturing and repair of main constructions operating at

R, UC, MR ISO E24.60.10Mn2B20,DIN EL-NiCr24Mo10Mn2

78

temperature up to 600C.АНЖР-2

(ANZHR-2) =/+/ 3...5 GOST 9466-75, Specification 14-4-598-75,08Х24Н40М7Г2

Welding of dissimilar steels (high-alloyed, heat resistant with low-alloyed, creep resistant) and also for welding of quenched steels at manufacturing and repair of main constructions operating at temperature up to 550C.

R, UC ISO E24.40.8Mn2B20,DIN E24.40.8Mn2B20

ОЗЛ-25Б(OZL-25B) =/+/ 3...4 GOST 9466-75,

GOST 10052-75, Э-10Х20Н70Г2М2Б2В

Welding of corrosion and heat resistant alloy ХН78Т (ЭИ-435) (ХN78Т (EI-435)) of cold resistant dissimilar steels.

R, UC, MR AWS ENiCrFe-2,DIN EL-NiCr15MoNb

ОЗЛ-8C(OZL-8C) =/+/ 3...4 GOST 9466-75,

Specification 1273-092-00187197-97

Welding of constructions from corrosion resistant chrome-nickel steels for wide application of 08Х18Н10 (08Х18N10), 12Х18Н10Т (12Х18N10Т) trade names and others similar to them. They are used for containers, storehouses, plants of food and textile industry.

R, UC ISO E19.9.1CoWS20,DIN E19.9.1CoWS20

НИИ-48Г(NII-48G) =/+/ 3...5 GOST 9466-75,

GOST 10052-75, Э-10Х20Н9Г6С

Welding of low-alloyed, high-manganese dissimilar steels of type 110Г13Л (110G13L).

R AWS E307-15,ISO E18.8.MnB20,DIN E18.8Mn6B20

Electrodes for depositionЭН-60М

(EN-60М) =/+/ 2,5...5

GOST 9466-75, GOST 10051-75, Э-70Х3СМТ

Deposition of all kinds of dies and also for quickwearing details of machinery rebuilding, fair-leaders, eccentrics, gear-wheels etc. They ensure hardness 53-61 HRCЭ on the fifth layer.

R, UC, MQ DIN E2-UM55-GT

ЦН-6Л(TSN-6L) =/+/ 4; 5 GOST 9466-75,

GOST 10051-75, Э-08Х17Н8С6Г

Deposition of thickening surface details of the armature of boilers operating at temperature up to 570C and presure up to 78MPa.

R

ЦН-12М-67(TSN-12М-67) =/+/ 4; 5 GOST 9466-75,

GOST 10051-75, Э-13Х16Н8М5С5Г4Б

Deposition of thickening surface details of the armature of power supply systems operating at high pressure and temperatures up to 6000C

R

79

ЦНИИН-4(TSNEEN-4) =/+/ 4 GOST 9466-75,

GOST 10051-75, Э-65Х25Г13Н3

Deposition and rewelding of casting of railway remotely spiders and other details of high-manganese steels of Г13 (G13) and 110Г13Л (110G13L) trade names. They ensure hardness of all-weld metal 25-37 HRCЭ in a reset state

R DIN E8-UM300-P

ОЗН-300М ~, =/+/ 4; 5 GOST 9466-75, Specification 14-168-68-88, 11Г3С

Deposition of details from carboned and low-alloyed steels operating in conditions of abrasion of metal on metal. They ensure hardness of all-weld metal 270-360HB on the fifth layer.

R, UC DIN E1-UM300-P

ОЗН-400М ~, =/+/ 4; 5 GOST 9466-75, Specification 14-168-67-88, 15Г4С

The same application. They ensure hardness 360-430 HB on the fifth layer.

R DIN E1-UM400-P

Т-590 ~, =/+/ 4; 5 GOST 9466-75, GOST 10051-75, Э-320Х25С2ГР

Deposition of details operating in conditions of abrasive wear. They ensure hardness 58-64 HRCЭ

R, UC DIN E10-UM60-G

ОЗН-6(OZN-6) ~, =/+/ 4; 5 GOST 9466-75,

Specification 14-168-69-88, 90Х4Г2С3Р

Deposition of details operating under impact load. They ensure hardness 53-61 HRCЭ on the fifth layer.

R DIN E2-UM60-GP

ОЗШ-8(OZSH-8) =/+/ 3; 4 GOST 9466-75,

Specification 1272-083-00187197-96,11Х31М3ГСЮФ

Deposition of hardly loaded forge - formed fitting-out of hot deformation. They ensure hardness 51-57 HRCЭ on the fifth layer.

R, UC DIN E9-UM250«55»-TZ

Electrodes for welding of non-ferrous metalsОЗА-1 =/+/ 4; 5 Specification

14-4-614-75Welding and deposition of details and constructions from technical pure aluminum of A0, A1, A2, A3 trade names.

R AWS E1100,DIN EL-Al99,5

ОЗБ-2М (OZB-2M) =/+/ 3; 4 Specification

1272-082-00187197-95

Welding and deposition of bronzes, deposition on steel and bronze and for rewelding of bronze and pig-iron casting.

R AWS ECuSn-C,ISO ECuSn2B2,DIN ELCuSn6

80

АНЦ/ОЗМ-3(ANTS/OZM-3) =/+/ 4; 5 Specification 14-4-

1270-84Welding and deposition without heating or with slight preheating of constructions from pure copper.

R AWS ECu-15

Комсомолец-100

(Komsomolets-100)

=/+/ 3…5 Specification 1272-097-36534674-98

Welding and deposition of technical pure copper of M1, M2, M3 trade names and welding of copper with steel.

R

Electrodes for welding and deposition of pig-ironМНЧ-2

(MNCH-2) =/+/ 3...5 Specification 14-4-780-76

Welding without heating, rewelding of casting and deposition of details from grey, high-strength and forgeable pig-iron. They are preferable for welding of compounds for which high requirements to cleanliness of surface after treatment is a must.

R, MR AWS ENiCu-B,ISO ENiCu2BG2,DIN ENiCuG3

ЦЧ-4(TSCH-4) ~, =/+/ 3...5 Specification

14-4-831-77Cold welding of details from high-strength pig-iron with spherical graphite and grey pig-iron with plate graphite and also for their combinations with steel. An all-weld metal is modified steel

R, MR, MQ

ОЗЧ-6(OZCH-6) =/+/ 2...5 Specification

1272-091-00187197-96

Welding without heating of constructions from grey and forgeable pig-iron. They are preferable for repairs to through defects especially in thin-wall details. An all-weld metal is copper-base alloy.

R, MQ

Electrodes for cutting ОЗР-1

(OZR-1) ~, = 3...5 Specification 1272-096-00187197-97

Cutting of steels of any trade names (including armature, high-alloyed), pig-iron, copper alloys

R

ОЗР-2 (OZR-2) ~, = 3...5 Specification 1272-

090-00187197-96Cutting of steels of any trade names (including armature, high-alloyed), pig-iron, copper alloys

R, MQ

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RUSSIAN WELDING SOCIETY

Moscow region office of RWS

Association of main welders of Moscow

In honour of the 10 year anniversary of Russian scientific and technical welding society

PRESENTin the second half of the year 2002

the 1st Moscow International Exhibition «Welding»(staff, equipment, technique)

the 1st Moscow International scientific and practical conference « Welding-Quality-Competitiveness»

(staff, equipment, technique)

RWS management

Please call for reference: +7 (095) 173-98-21;fax: +7 (095) 173-07-87; E-mail: market@melon.ru;WWW: http://www.melon.ru.address: 41, Volgogradskiy prospect, Moscow, 109316

the general sponsor of exhibition and conference

«JSC SpetsElectrode»

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