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Welding electrode extrusion pilot plant is used to manufacture Shielded Metal Arc Welding electrodes for various materials including Carbon steels, stainless steel, low alloy steels and nickel based alloys and so in different sizes such as 2.5 X350 mm, 3.15X350 mm, 4.00 X450 mm and 5.00 X 450 mm. It includes the following machineries like

• Dry mixer

• Wet mixer

• Briquetting ( slug press)

• Extruder [ it includes wire feeder ,conveyor and eccentricity tester also]

• Electrode baking oven

• Wire cleaning machine

• Rod decoating machine (flux stripping)

Dry mixer:

• The flux ingredients ( like Rutile, Low carbon Ferro Manganese, Cellulose, Titanium Di-Oxide, Mica, Feldspar, quartz, etc.) , are weighed accurately depends upon the type of electrodes and they are mixed without any binder by using this machine to get homogeneous mix. The type of dry mixer is“ribbon blender”.


Capacity : 25Kgs

Make: Gangaa Machines.

Wet Mixer:

• These mixers are used to blend dry powder of flux with binders to obtain homogeneous wet mixture. The type of mixture is “Double roller”.

Model :

Capacity : 25 kgs

Make : Gangaa machines

Briquetting press:

• The wet mixed paste filled in the cylinder and compacted by applying pressure. It produces briquettes (cake). Model :

Capacity : 25 kgs

Make : Gangaa machines

Electrode Extruder: [Includes wire feeder and conveyor ]

• The coating of flux is done by the extrusion press in which the flux fed through a cylinder under pressure. While the wire is fed from the wire magazine of the electrode press the briquettes are introduced into the extrusion cylinder of the press. During extrusion the core wire is fed one by one from wire feeder and coated with the flux by way of nozzle/die box system incorporated in the extrusion press. The electrodes coming out from the press are tested in an eccentricity tester.

• The electrode coming out from the press is passed through a conveyor to the brushing machine for brushing of holding end and cleaning the same on tip end side for easy striking. After that the electrodes are spread on the collecting tray for air drying.

Model :

Capacity :

Make: gangaa machines

Rod decoating (Flux stripping) Machine:

• The rejected electrodes ( after passed the eccentricity test) are taken into the flux stripping machine where the flux is stripped off. The core wire and flux can be re-used.

Model :

Make : Gangaa machines

Wire Cleaning Machine:

• The wire cleaning/ washing machine is used to eliminate the coating of flux from the core wire.

Model :

Make : Gangaa machines

Electrode baking oven:

• After the air drying the electrodes where stacked in to the trays and are fed into the oven for certain period to remove excess moisture. The baking oven Temperature range is 5000C.

Model :

Make : Gangaa machines.

Eccentricity Tester :

• These are used to check the concentricity of flux coating around the core wire.

Model :

Make : Gangaa machines


The purpose of Gleeble 3500 is to simulate Continuous casting, Mushy zone Processing, Hot Rolling, Forging, Extrusion, Weld HAZ Cycles, Upset Butt Welding, Diffusion Bonding, Continuous Strip Annealing, Heat Treatment, Powder Metallurgy Sintering and Synthesis. Application includes Hot Tension and compression testing including uniaxial compression, plane strain compression and strain induced crack opening, developing stress vs strain curves, melting and solidification, nil strength testing, hot ductility testing, thermal cycling / heat treatment, dilatometry / phase transformation, stress relaxation studies, creep rupture and fatigue analysis.


Gleeble 3500 is a fully integrated digital closed-loop control thermal and mechanical testing system, coupled with Windows based computer software, combined with an array of powerful processors, provides an extremely user-friendly interface to create, run and analyze data. The direct resistance heating system of the Gleeble 3500 can heat specimens at rates of up to 10,000°C/second, or can hold steady-state equilibrium temperatures. High thermal conductivity grips hold the specimen, making the Gleeble 3500 capable of high cooling rates. An optional quench system can achieve cooling rates in excess of 10,000°C/second at the specimen surface. Thermocouples or an optional infrared pyrometer provide signals for accurate feedback control of specimen temperatures. Because of the unique high speed heating method, Gleeble systems typically can run thermal tests 3 to 10 times faster than conventional furnace equipped machines.


Dynamic Systems Inc.,Poestenkill, New York, USA


• The on-line data acquisition and statistical analyses of the transient process signals u(t) and i(t) with the ANALYSATOR HANNOVER give objective statements for optimization of welding processes, welding equipment, filler materials and consumables.

• Evaluation of coated electrodes


ANALYSATOR HANNOVER realizes by statistical analyses of arc welding processes.

• For investigating and optimizing of arc welding processes (welding parameters: voltage, current, welding speed etc.), power sources and filler materials (stick electrodes, wires etc.) and consumables (gases, fluxes etc.)

• The ANALYSATOR HANNOVER (AH-XXVI) together with the FUZZY MONITOR HANNOVER (FMH II) and the DATA EVALUATION & MANAGEMENT SYSTEM (AH-DEM) are powerful tools for quality assurance in arc welding.


Material Characterization


Leica DMi8C is having the Focus of Manual 3-gear with focus stop and torque adjustment and the Objective turret is 6-fold M25 coded the Reflector turret is 6-fold reflector turret coded. The Reflected light axis is Manual Which Includes centerable field and aperture iris diaphragm and manual UC-3D and Illumination, slot for polarizer and additional filter slider. The Stage of DMi8C having Fix stage with different inserts and Manual 3-plate stage with different inserts Gliding stage. The Controlments are the Stand Intensity control IL/TL switch. The Contrasting techniques are Incident light (IL) - BF, UC-3D, HDF, DIC, Pol, Fluorescence and Transmitted light (TL) - BF, Pol, Ph, DIC, DF. The Illumination source are LED. The Reflected light axis are Manual Includes centerable field and aperture iris diaphragm and manual UC-3D Illumination, slot for polarizer and additional filter slider. The magnification ranges from 50X to 1000X.

Make: Leica

Model: DMi8 Coded

Made in Germany


Material Characterization

Equipment Description

• HARDNESS ranges are as per the following standard DIN EN ISO 6507, ASTM E-384, ASTM E92- HV 0.00025, HV 0.005, HV 0.001, HV 0.002, HV 0.005, HV 0.01, HV 0.02, HV 0.025, HV 0.05, HV 0.1, HV 0.2, HV 0.3, HV 0.5, HV 1, HV 2, HV 3, HV 5, HV 10

• KNOOP hardness ranges are as per the following standard DIN EN ISO 4545, ASTM E-384, ASTM E92- HK 0.00025, HK 0.0005, HK 0.001, HK 0.002, HK 0.003, HK 0.005, HK 0.01, HK 0.02, HK 0.025, HK 0.05, HK 0.1, HK 0.2, HK 0.3, HK 0.5, HK 1, HK 2.

6-Fold Measurement Turret

The 6-fold measurement turret is supplied as standard in all models and offers space for various test methods. For example, it can be equipped with 3 different magnification lenses and the corresponding penetrators for Vickers, Knoop or Brinell.

Dynamic Hight Adjustment

The electronic movement control allows quick, accurate and sensitive positioning of the test head. Forceless, precise and collision-proof positioning of the test head via rotating the control knob. (0.01 up to 20 mm/s). An additional Z-axis makes this helpful function possible.

Contour Scan

Users can choose whether to approach the entire section or a partial segment of a contour. The measurement lens scans the entire route and stores all data in the program. Subsequently, a chosen number of the test points can be programmed into the system, or at chosen distances, relative to the edge. This programming enables the hardness testing sequence to be conducted completely automatically.

2D/3D Plane Hardness Chart

Hardness distribution across partial segments or whole planes of test samples. Colourized representation in 2D and perspectively free twistable 3D on sample image.

Edge Recognition

Working with program templates and the edge recognition software module makes fine-positioning of test rows irrelevant. The machine moves to the start points automatically and corrects their positions before the test sequence is started.

Make: Qness &Model: Q10A+

Made in Austria


• Defect detection and categorization

• In-situ monitoring of composition and phase transformation

• Improved weld quality

• Insight to the physics

• Fast signal processing capability

• Insensitive to ambient disturbances

• Data documentation for post processing

• Reduction in cycle time


• The Smart Optical Monitoring System (SOMS), when installed on a 3D Printing (or a welding) CNC (or robot) machine, observes in real time the plasma generated during a material deposition or welding operation.

• By performing a multi-spectrum analysis, it identifies and categorizes different types of defects, and then essentially “teaches” the host 3D Printing (or welding) equipment to avoid those defects and to create better welds or material depositions with the desired composition and phase transformation.

• Ability to make weld characterization with respect to weld metal composition, phase transformation, introduction of welding defects etc. in real time based on analysis of optical spectrum during arc welding.


Specimen preparation

Equipment Description:
There are four types of equipments available to prepare the samples.

1. Belt Grinder

3. Grinding Machine

3. Grinding Machine

5. Abrasive Cutting Machine

1. Belt grinding The purpose of the rough belt grinding step is to remove the damage produced during cutting and planar grinding. Proper rough polishing will maintain specimen flatness and retain all inclusions or secondary phases. By eliminating the previous damage and maintaining the microstructural integrity of the specimen at this step, a minimal amount of time should be required to remove the cosmetic damage at the final polishing step.

2.The mounting operation accomplishes three important functions

• It protects the specimen edge and maintains the integrity of a materials surface features

• Fills voids in porous materials and

• Improves handling of irregular shaped samples, especially for automated specimen preparation.

3.The grinding machine is required to polish the specimen by various emery sheets which reduces the damage created by sectioning. The grinding machine step is accomplished by decreasing the abrasive grit/particle size sequentially to obtain surface finishes that are ready for polishing.

4.The purpose of the polishing machine is the final step to bring the mirror image of the sample. Proper fine polishing will maintain specimen flatness and retain all inclusions or secondary phases. By eliminating the previous damage and maintaining the microstructural integrity of the specimen at this step, a minimal amount of time should be required to remove the cosmetic damage at the final polishing step.

5.Most metallographic samples need to be sectioned to the area of interest and for easier handling. Depending upon the material, the sectioning operation can be obtained by abrasive cutting (metals and metal matrix composites). High speed cut off wheel is used to cut the specimens in proper dimensions.

Make: Chennai Metco

1. Belt Grinder : BAINLINE - GP

2. Hydraulic Specimen Mounting Press : BAINMOUNT - H

3. Grinding Machine : BAINPOL - VTD

4. Polishing Machine : BAINPOL - VTD

5. Abrasive Cutting Machine : A10 – 100

Made In India

Material Characterization

Equipment Description

ZEISS Stemi 508 is your compact, reliable Greenough stereo microscope. Equipped with apochromatic optics you acquire images of outstanding image contrast and color accuracy. Its mechanics is designed for heavy workloads. With the large up to 36 mm object field you always keep the overview of your sample. The 8:1 zoom then allows to bring details up to 50× magnification. Add interchangeable optics and observe an area of up to 122 mm. Stemi 508 offers better ergonomics than any other Greenough-type stereo microscope: The low viewing angle of 35° lets you keep a relaxed posture even after hours of work.With ZEISS Stemi 508 you observe and document your samples exactly as they are: rich in detail, sharp in focus and free from distortion or color fringes. Stemi 508 is your robust all-rounder for everyday lab work and industrial inspections.

Make: Zesiss & Model: Stemi 508

Made in Germany


Aside from designing new alloys and materials, understanding how to process them and join them is also a critical factor to consider before the new materials can be deployed. Applications related to joining include welding, soldering and brazing. Each of these processes is driven by the underlying thermodynamics, although in most cases they tend to be non-equilibrium in nature, hence kinetic considerations need to be taken into account also.


• Liquid – gas equilibrium

• Liquid – slag equilibrium

• Inclusion formation

• Liquid-solid interactions

• Predicting phases formed during equilibrium and non-equilibrium solidification

• Predicting phases formed during equilibrium and non-equilibrium solidification

• Prediction of heat affected zone grain boundary liquation

• Understanding phase stability in the heat affected zone for dissimilar materials and dilution affects

• Identifying potential filler wire materials

• Predicting thermodynamic properties such as heat evolved, specific heat latent heat during solidification that can be used as input parameters to welding simulation models.

• Modelling thermodynamic and phase equilibria of solders, including the potential to form intermetallic compounds

Diffusion module (DICTRA)

• Investigating the rate of cooling on the fraction solid curves and micro-segregation during solidification

• Simulating post-weld heat treatment

Thermo-Calc has gained a world-wide reputation as the best and most powerful software package for thermodynamic calculations. It is widely used for a variety of calculations including calculating:

• Stable and meta-stable heterogeneous phase equilibria

• Amounts of phases and their compositions

• Thermochemical data such as enthalpies, heat capacity and activities

• Transformation temperatures, such as liquidus and solidus

• Driving force for phase transformations

• Phase diagrams (binary, ternary and multi-component)

• Solidification applying the Scheil-Gulliver model

• Thermodynamic properties of chemical reactions


Thermo-Calc Software AB, SWEDEN