Process of welding with consumable and non-consumable electrodes provides for use of protective gaseous medium. Mostly pure gases such as argon and carbon dioxide are used. In recent 10-15 years big enterprises have started to use welding mixtures. For welding thick low-alloy steel the most used mixture is 82% of argon and 18% of carbon dioxide. This mixture improves physical and mechanical properties of a weld due to more stable arc that improves weld penetration and ash carryover, increases the welding speed and reduces metal spatter.
After the switch to welding mixtures, delivered in cylinders, managers of many companies wonder: how to ensure the weld seam stability, how to reduce cylinder delivery and maintenance costs, where to station increasing number of cylinders etc.?
All these problems are possible to avoid by preparing welding mixtures with liquefied gas in the enterprise.
AvtoGasTrans offers systems for preparation of welding mixtures in the enterprise. The main advantages of mixture preparation on site compared to mixture delivery in cylinders.
- stability of mixture composition. The welding mixture production on site unlike its delivery in cylinders, allows to maintain stable mixture properties i.e. percentage (wide adjustment range), pressure, temperature, consumption. These factors influence the quality of a weld seam.
- reduction of mixture cost. The cost of mixture produced from liquefied components on site is several times less than the cost of cylinder mixture.
- reduction of man-hours and increased safety; process with no need to change cylinders, working pressure reduction.
- a drastic reduction of transportation costs. When delivering liquid argon and carbon dioxide, you don’t need to transport filled cylinders: only 30% of their weight is the weight of product, 70% is the weight of cylinders.
- absence of cylinders delivery and maintenance costs.
- conformity with all welding equipment requirements.
Our company offers you systems for on-site production of two-part (CO2 + Ar), three-part (CO2 + Ar + O2) welding mixtures. System’s capacity is 50, 100 or 200 mі/hr. Our systems will allow you to make welding mixtures in your enterprise.
Economically, there is a double benefit. Gas is delivered in liquid state, and then it is gasified on site, which allows to exclude transportation in 40l cylinders (e.g. 1 ton of liquid argon or carbon dioxide gives gas of the volume equal to 110-120 cylinders).
The use of welding mixtures in your enterprise allows to minimize spatter and reduce seam finishing costs, increase seam plasticity and strength, stabilize welding process and improve microstructure of weld metal, improve seam appearance, save on weld wire, increase the welding speed, improve work conditions of welder, increase half as much labor productivity, reduce operating costs by 20%.
The integrated typical scheme of a complex on manufacture of a welding mix by productivity 20... 500 m3/hour:
- Gasificator of Argon (1,5 - 25,0 м3);
- Transport Tank for Liquid Argon (1.6:8.0 м3);
- Liquid CO2 Storage Tank RDKh-10,0-2,0; RDKh-12,5-2,0; RDKh-22,5-2,0; RDKh-30,0-2,0; RDKh-40,0-2,0; RDKh-50,0-2,0;
- Liquid Transport CO2 Tank (4,0:18,0 м3) RKhTU-4,0-1,8; TsZhU-10-2,0; TsZhU-18-2,0; TsZhU-22-2,2;
- Liquid CO2 Transfer Station AGT 141-01;
- Equipment room (preparation and mixture of components);
- Shop - the consumer.
The Typical set of the equipment of a complex on mix manufacture:
Ar equipment:
- Transport capacities for argon delivery in the liquid state from 2 to 10 tons depending on consumption;
- Vaporizers for storage of liquid argon and its subsequent gasification from 1 to 10 tons.
СО2 equipment:
- Transport capacities for delivery СО2 in the liquid state RKhTU-4,0-1,8; TsZhU-10-2,0; TsZhU-18-2,0; TsZhU-22-2,2 depending on consumption;
- Vaporizers productivity from 100 to 1200 kg/hr;
- Heaters and reducers for achievement of demanded parameters.
The Equipment for mix preparation:
- Gas-mixers of firm WITT-Gasetechnik productivity 50, 100, 200 m3/hr a ready mix;
- The Receiver with the complete set of control devices and automation of parameters of a welding mix.
System of the automated account and the control of technological parameters of a mix:
Allows to supervise technological parameters (the expense, temperature, pressure) gases with possibility of a conclusion to the remote computer of the person on duty power.
Pipelines of distributing and giving welding mix in industrial shops:
- Horizontal shop collectors with stop valves;
- Pipelines feed to workplaces;
- Demontable posts from 1 to 3 workplaces;
- Control Device Constant Pressure provides a constancy in percentage parities of a mix on all modes of consumption.