Copper- one of the oldest known metals, which was used several thousand years ago. Many consider it universal and still, therefore, the widespread use of copper in our time does not surprise anyone. Looking at the widespread use of copper, you may be thinking about welding some copper product.
Copper has a number of excellent qualities that are not characteristic of other metals. These include high electrical and thermal conductivity, corrosion resistance and ductility. Also to her technical qualities aesthetics can be attributed, because of which the metal is very much in demand in decorative finishes.
So, copper welding is a very popular business, because copper has a wide application. However, copper welding electrodes cost a lot of money, and many people find a way out in making homemade electrodes for their own use. In order to weld copper, you need to clean the copper surface of the metal from oxidation, because copper is a highly oxidizable metal. Also, when welding copper, you need to use all kinds of additives, such as silicon or phosphorus.
Since copper has poor casting properties, it is recommended to use filler materials. The materials used are mainly in large numbers contains phosphorus, zinc, sometimes silver, etc. For welding copper, carbon electrodes are almost always used, which are famous for their low price and quality.
In order to make do-it-yourself electrodes for copper welding You need, first of all, to stock up on all the materials that are needed in order to make the right coating. These materials are: ferromanganese 50%, fluorspar 10%, liquid glass 20% and 8% ferrosilicon. All these components must be thoroughly mixed and applied to the electrode rod in an equal layer. The rod itself should be made of a copper rod 30 - 40 centimeters long.
You can apply a layer of coating by simply dipping it into the solution or making a special device that will press the rod. However, many people do not make such sacrifices and buy ordinary carbon electrodes or apply the coating by dipping the rod into the liquid mass of the coating. After coating the electrode, it must be allowed to dry, and then it must be placed in a special oven for calcining electrodes at a temperature of 500 - 600 degrees for 50 minutes or one hour.
After annealing, the electrodes must cool down from optimal temperature and completely ready to use. However, it seems to many people that it is difficult and time-consuming to make electrodes on their own. so they are ready to buy them from us. If you consider yourself one of these people, then you can make a purchase from our
The carbon content of cast iron makes it difficult to weld. With the wrong approach, deep pores and cracks may appear at the junction, and indeed, the workpiece to be welded can be easily damaged.
For this reason, special requirements are placed on the welding of cast iron, one of which is the use of a suitable type of electrode. Cast iron electrodes differ in the materials of manufacture. They can be made from both cast iron bars, steel wire, and copper with its alloys.
In this article of the site about MMA welding mmasvarka.ru it will be told about what types of electrodes for cast iron exist, and whether they can be made by hand, so to speak, at home.
Types of electrodes for welding cast iron
For welding cast iron products, special types of electrodes are used. If steel wire was taken as the basis for their manufacture, then the electrodes for cast iron are marked as follows - SV-08 A and SV-08. There are also so-called generic types electrodes for cast iron.
TsCh-4 - with electrodes of this brand, you can get an even and strong welding joint on cast iron and products made from it. TsCh-4 electrodes are applicable for welding at almost any temperature.
EMChS - for their manufacture, a low-carbon wire is used, on which a three-layer coating is applied during the manufacture of EMChS electrodes. Due to this, during the burning of the electrode, a gas protective layer is formed, which protects the welding seam from the formation of air bubbles and oxidation.
Ficast NiFe K electrodes - a special kind of electrode for welding cast iron and steel together. They are iron-nickel rods for high-quality welding of cast iron with steel.
MNCH-1 - electrodes of this series are made of an expensive alloy, which includes: copper, nickel and monel metal. Thanks to the use of these electrodes for cast iron, the seam is easy to further process, it does not form pores and cracks.
How to make do-it-yourself electrodes for cast iron
The cost of electrodes for welding cast iron is quite high, and today you can find high-quality Consumables to work with cast iron and products from it, it is quite difficult. Therefore, many experienced welders resort to one trick, they make cast iron electrodes on their own.
For their manufacture, copper wire up to 2 mm is required, and the most common electrodes for welding, for example, the same UONI, ANO-4 orUONI 13/45 . The process of converting conventional electrodes for welding cast iron is very simple. To make electrodes for cast iron with your own hands, you will need to wind copper wire to conventional electrodes. Thus, with conventional electrodes, it will be possible to cook cast iron.
An equally popular method of manufacturing electrodes for cast iron and using the following components:
- Liquid glass;
- Copper rods, up to 5 mm in diameter;
- Metal powder and crushed electrode coating.
The manufacturing process of home-made electrodes for welding cast iron using these components is as follows:
- Copper rods are cut to the required length, after which they are carefully cleaned with a fine sandpaper and degreased;
- A previously prepared and carefully crushed electrode coating is taken, which is mixed with fine metal filings (proportions: one to one). After that, approximately 30% of liquid glass is added to the resulting mixture;
- Next, cut copper rods are taken and lowered several times into a home-made coating for electrodes until their coating becomes approximately 2 mm thick;
- Then the electrodes are dried;
- And be sure before welding cast iron, home-made electrodes are calcined in electric oven. The temperature of calcining electrodes for cast iron is approximately 200 degrees plus.
As you can see, making electrodes for welding cast iron is not difficult at all. Thus, it will be possible not only to save on consumables for welding, but also to achieve best quality performance of work.
The production and sale of welding electrodes is a popular activity in Russia. Electrodes are consumables that are in demand in construction during the construction reinforced concrete structures, as well as in those industries where it is required to connect metal surfaces by welding. Relatively small financial investments at the opening stage and quick payback (from 1 to 3 years) are the main advantages of the enterprise, whose activity is the production and sale of welding electrodes.
Our business valuation:
Starting investments - from 2500000 rubles. and higher
Market saturation is high.
The complexity of starting a business is 8/10.
The main stages of the production of welding electrodes
An entrepreneur opening a mini factory for the production of welding electrodes needs to rent a room, purchase equipment and consumables. But you can buy machine tools and raw materials only after you have chosen the method of manufacturing products: coating or pressure testing.
Generally, technological process, in which a thin coating layer is applied to a metal rod, is not complicated and consists of several stages:
- production of a workpiece - a metal rod;
- preparation of the coating mixture;
- applying a coating to the workpiece;
- drying.
Production of electrodes at home: coating method
Coating is a method that can be used in the production of electrodes at home, in small batches. The main device responsible for quality finished products, is a drying cabinet. The cost of a drying cabinet varies from 1,230 rubles. (simple pencil case) up to 22,000 (powerful electric furnace).
Materials used for the manufacture of electrodes:
- special wire, a certain diameter;
- chalk with additives;
- potassium or sodium lump.
Special steel wire for the manufacture of electrodes, of the desired diameter and length, is straightened and cut into equal pieces. All operations are carried out on automated equipment.
The surface of the obtained blanks must be carefully cleaned with sandpaper. removed during processing. upper layer metal, and the surface of the wire becomes clean and slightly rough, which guarantees high-quality adhesion to the coating.
The coating solution is a homogeneous mass mixed from different components, one of which is liquid glass made from silicate block. It is important to remember that all substances must be in powder form.
Chalk and other additives go through certain stages of grinding on a roller or crushed stone crusher:
- rough crushing, as a result of which, substances are divided into large pieces;
- grinding to obtain a powdery mass (fine grinding);
- screening with special sieves.
This will create a homogeneous mixture that will lie evenly on the electrode and adhere well to metal surface blanks. Next, the metal rod is lowered into the finished solution, and then subjected to double drying.
Manufacture of electrodes by crimping
But the coating method used at home is not suitable for making electrodes on a scale industrial production. It is unlikely that large companies in need of large quantities of welding material will buy "handicraft" products, without a certificate and accompanying documentation, even if they are of good quality.
Therefore, at an enterprise that has plans for further development and expansion, it is preferable to apply the technology for the production of electrodes by the crimping method. Since the product obtained in this way, as much as possible meets modern requirements and standards for welding consumables.
Crimping is the manufacture of welding electrodes using special presses, where they are exposed to high pressure(from 300 to 650 kgf / sq. cm). The process consists in pulling a metal workpiece (electrode wire) through the holes in the installation cylinder, which is filled with a coating solution.
Finished products are checked for defects, the ends are cleaned. Only then are the electrodes labeled and packaged. The waste left after the operation of the scrap cleaning machine is sent for processing, and then launched into the production of the next batch of products.
To organize a mini workshop, a line for the production of medium power electrodes is required, including:
- bar feeder;
- GEP - hydraulic electrode coating press;
- cleaning plant.
Additional devices:
- MPE - electrode feeding mechanism;
- MZT - cleaning and transportation mechanism;
- PRA - straightening-chopping machine, equipped with a receiving hopper and a wire unwinder;
- BP - briquette press;
- MOB (10) - mechanism for cleaning raw defective electrodes;
- MS (50) - wet mixer.
The price of equipment for electrodes varies from 6,800,000 to 8,000,000 rubles.
It should be noted that the coating is a necessary component of the electrode, which contributes to the uniform melting of the metals being welded. And the slag crust formed during the welding process blocks the access of oxygen to the joint, which avoids rapid loss temperatures on the surfaces to be welded. The result is a perfectly even seam, without bubbles and microcracks.
Production of graphite electrodes
More difficult is the production of carbon electrodes, the manufacture of which requires a large amount of energy (current 60-120 kA), complex expensive equipment and time. This causes the high cost of finished products.
Carbon or graphite electrodes are made from the following materials:
- low-ash petroleum coke (about 85%);
- electrode battle (about 15%);
- coal tar pitch (as a binder).
The components go through the stages of crushing, calcining, grinding, fractionation, dosing and mixing. Next, the electrode mass is processed in powerful horizontal presses. The obtained green electrodes are dried, fired and graphitized.
Roasting is carried out for 12 - 33 days at a temperature of 1525 to 1625 K without oxygen. As a result, coal tar pitch is converted into coke, providing an increase in the thermal and electrical conductivity of the finished product, as well as improving the mechanical characteristics of the electrodes.
Graphitization lasts more than 100 hours at temperatures from 2700 to 2900 K.
The most expensive part of the project is the acquisition of the production line. Therefore, before buying equipment for the production of welding electrodes, it is necessary to carefully analyze the state of the market in the opening region, calculate the amount of initial investment and choose the optimal manufacturing technology.
It is advisable to first find clients, which are usually:
- specialized stores;
- firms engaged in the manufacture of metal structures;
- private workshops.
You can save money by buying used equipment. But in this case, you need to carefully check the documentation (technical condition, number of repairs), find out about the reasons for the sale.
Calculation of profit from the production and sale of electrodes
A novice businessman who does not have the opportunity to purchase a modern production line is better to start with a small production. But this will also require renting a room for installing equipment (for example, drying cabinet, a press and containers for the preparation of a coating mixture) and the purchase of a minimum set of devices. In this case, the costs will be from 2,500,000 rubles. and higher. This includes the purchase of equipment, delivery, launch, purchase of raw materials, salaries of employees, advertising, packaging, and more.
According to experts, the profitability of such a business is 30%.
The cost of electrodes varies depending on the region and averages 400 rubles. per package (5 kg) or 80 rubles. for 1 kg. The cost price is about 50 rubles. for 1 kg. By using modern devices it is possible to produce about 500 kg of finished product per day.
From here:
- daily revenue will be about 25,000 rubles. (500x50),
- per month - 750,000 rubles.
Based on profitability, net profit will be about 230,000 rubles. per month (750,000 / 30). The enterprise will fully pay off in 10-12 months.
Copper- one of the oldest known metals, which was used several thousand years ago. Many consider it universal and still, therefore, the widespread use of copper in our time does not surprise anyone. Looking at the widespread use of copper, you may be thinking about welding some copper product.
Copper has a number of excellent qualities that are not characteristic of other metals. These include high electrical and thermal conductivity, corrosion resistance and ductility. Also, its technical qualities include aesthetics, because of which the metal is very much in demand in decorative finishes.
So, copper welding is a very popular business, because copper has a wide application.
Is it possible to make a welding electrode with your own hands?
However, copper welding electrodes cost a lot of money, and many people find a way out in making homemade electrodes for their own use. In order to weld copper, you need to clean the copper surface of the metal from oxidation, because copper is a highly oxidizable metal. Also, when welding copper, you need to use all kinds of additives, such as silicon or phosphorus.
Since copper has poor casting properties, it is recommended to use filler materials. Materials are mainly used, which contain a large amount of phosphorus, zinc, sometimes silver, etc. For welding copper, carbon electrodes are almost always used, which are famous for their low price and quality.
In order to make electrodes for welding copper with your own hands, you need, first of all, to stock up on all the materials that are needed in order to make correct coverage. These are the following materials: ferromanganese 50%, fluorspar 10%, liquid glass 20% and 8% ferrosilicon. All these components must be thoroughly mixed and applied to the electrode rod in an equal layer. The rod itself should be made of a copper rod 30 - 40 centimeters long.
You can apply a layer of coating by simply dipping it into the solution or making a special device that will press the rod. However, many people do not make such sacrifices and buy ordinary carbon electrodes or apply the coating by dipping the rod into the liquid mass of the coating. After coating the electrode, it must be allowed to dry, and then it must be placed in a special oven for calcining electrodes at a temperature of 500 - 600 degrees for 50 minutes or one hour.
After baking, the electrodes should cool down from the optimum temperature and are completely ready for use. However, it seems to many people that it is difficult and time-consuming to make electrodes on their own, so they are ready to buy them from us. If you consider yourself one of these people, then you can make a purchase from our manufacturing plants, which produce only high-quality products. In order to place an order, go to the "Contacts" menu item and make the necessary order at a reasonable price.
About Electrodes
Wire for electrodes
How to cook aluminum with electrodes at home
Every welder knows that welding without electrodes is impossible, and high-quality welding is impossible without high-quality electrodes, so it is necessary to purchase high-quality welding electrodes in order to weld on highest level. However, situations arise when it is not possible to purchase welding electrodes, but there are many improvised means. Is it possible to do without a welding electrode manufacturer? Let's find out about it from this article.
The electrodes are not so difficult to make. For manufacturing, you need to choose welding wire suitable diameter to create a welding electrode. After selecting the wire, it must be cut into pieces of 350 millimeters and cleaned with sandpaper. After that, it is necessary to prepare a coating, which consists of liquid glass (silicate glue) and crushed chalk.
To keep the coverage even. It is necessary to immerse the electrode wire in the coating vertically and leave a clean end 30–35 millimeters long under the top. After that, the electrode should be slowly removed and hung on a rope to dry. After complete drying and hardening, you get fully functional welding electrodes.
When welding is done at home, a satisfactory result is obtained when using the contact method of aluminum welding. This type of welding is performed with continuous flashing on electrically conductive machines. It is also possible to carry out seam welding of aluminum, but this requires a machine of high power and with special ion interrupters. Using such methods can be difficult at home, but some welders do use them.
When welding at home, you should not forget that it is necessary to observe safety precautions and strictly comply with all requirements.
Welding at home: an experiment with an electrode
The first thing to pay attention to is the insulation of all wires that take part in the welding process and are energized.
Conducting welding work at home, it is required to use gloves or mittens that will protect your hands from burns. From the blow electric shock Rubber boots will insure you. When carrying out welding work, it is imperative to wear a special mask to protect your face from sparks, coals and burns. In no case should you store flammable and flammable materials and objects in the room in which you are going to carry out welding work.
If the room has a wooden floor, then it should be protected from ignition with sheet metal. Be sure to put a fire extinguisher or a bucket of water near the place where you are going to weld. Due to the possible formation of harmful gases or other hazardous compounds, it is necessary to regularly ventilate the room in which you are welding.
Many people ask if it is possible to make an electrode for welding ferrous metals with your own hands at home?
The answer is no. You will not make a normal electrode for welding on your own. Because this is a rather science-intensive process, and the components that make up the coating cannot always be purchased at the nearest store.
What does the great and terrible Internet offer us in this regard?
Numerous welding websites claim that making an electrode is not a problem. If you do not go into the details of such production, you will need a steel bar, chalk, crushed to a powder state (fine fractions). Liquid glass (silicate glue) is applied to the rod, then the whole thing is sprinkled with chalk and rolled in so that it evenly sticks to the surface of the rod. It turns out a chalk layer of some thickness. Homemade is sent to the oven, oven or dried with a hairdryer.
And can this be cooked?
From our point of view it is impossible. With the same success, you can cook with a nail, fittings or a bare metal rod. No difference. The process of such welding is unstable, the seam will hardly be called such, and the slag will be practically absent due to the absence of slag-forming elements in the composition of the coating.
If we are to do it ourselves, then it is better to use the idea proposed a hundred years ago by two Americans. They came up with the idea of simply wrapping the rod with paper and sticking it on liquid glass. At least it's easier than fiddling with chalk. And the idea is very simple. Paper burns, emits smoke, which protects against harmful influence oxygen. Also, such a coating somehow improved the ignition and had a positive effect on the stability of the arc ... And this, of course, is very doubtful. Since easy ignition electric arc and the maintenance of its combustion is due to the low ionization energy of elements such as sodium, potassium and calcium.
In other words, you can not puzzle over the composition of the coating and the method of application. If you really want to cook, but there is nothing, and the shops are all closed for the holidays, take any piece of iron that is suitable in diameter and length, clamp it into an electrode holder and cook - you cannot call such a process welding, but it is quite possible to grab something in this way in extreme conditions. At least it's no worse than the options above.
