How Automated Flux Recovery Systems Improve Welding Efficiency & Reduce Costs
In fabrication processes like Submerged Arc Welding, flux plays a crucial role in protecting the molten weld from air contamination and stabilizing the arc. That being said, flux wastage is often an overlooked issue.
That being said, not all fluxes need to be discarded. Certain fluxes remain intact even after the process which can be collected and further reused. Many fabrication units unknowingly discard reusable fluxes, leading to increased material cost as flux isn’t cheap.
Automated flux recovery systems solve this issue by recovering, cleaning and reusing the flux. In this blog we will discuss how these systems help to improve weld efficiency and reduce cost.
What is Flux in Welding?
Let’s start with the basic question- what is flux in SAW? Flux is a granular material that is used in SAW welding to protect molten weld pool from contamination.
The flux is spread out all over the weld area submerging it completely, which later melts and forms a protective slag layer.
In the welding process only a portion of the flux is consumed, while a large amount remains scattered and unused. Without a proper recovery system the unused flux, which is quite costly, becomes wasted.
Impact Of Flux Wastage
Poor flux management can lead to costly consequences such as:
- Excessive spreading of flux
- Using contaminated flux leading to contaminated weld
- Manual clean up leading to increased downtime
- Additional expenses for flux handling and recovery
What Are Automated Flux Recovery Systems?
Automated Flux Recovery Systems are specialized accessories that collect, clean and recycle unused welding flux.
How Automated Flux Recovery System Operates
1. Vacuum Collection
The powerful suction system collects the unused flux from the welding area.
2. Filtration and Separation
The collected flux is then passed through a filter which removes the excess dust, slag particles and other metallic impurities.
3. Output- Clean and Reusable Flux
The clean flux is stored and then fed back during the welding process, creating quality and consistent welds.
Advantages of Automated Flux Recovery Systems
1. Efficient Workflow
Automated systems simultaneously collect the flux alongside the welding process. This does away with the need for manual clean up, thus ensuring minimal interruptions.
2. Minimal Downtime
The flux recovery happens at a fast pace- which means less waiting time amidst the operations thereby enhancing overall productivity.
3. Consistent Access To Flux
These systems ensure that operators consistently have access to clean and reusable flux.
4. Enhanced Weld Quality
These filtered fluxes minimize the defects, producing more stronger welds.
How Do These Systems Help Reduce Costs
1. Minimize Material Expenses
With the automated system up to 80% of flux is reused, which helps to minimize material expenses.
2. Reduced Labour Cost
Automated systems reduce the need for manual handling and sorting of the fluxes, thereby reducing the overall labour cost.
3. Equipment Longevity
Using clean flux will reduce the damage on welding equipment, thereby lowering maintenance cost.
4. Long-term Savings
While the initial investment of the automated flux recovery machine may seem, a quick ROI can be achieved through consistent savings.
Applications of Flux Recovery Machine
Automated flux recovery systems find their application in diverse industries that demands precision and efficiency, all while such as:
- Shipbuilding and marine fabrication
- Oil and gas infrastructure
- Structural steel manufacturing
- Heavy machinery production
- Pressure vessel fabrication
Conclusion
Smart resource management is a crucial factor that influences the overall welding efficiency. Automated flux recovery system is an excellent solution that reduces waste, maintains material quality and ensures control cost.
Are you looking to improve welding efficiency and reduce operational cost? Then RedRock is your destination. As the leading providers of welder and positioner solutions, we also offer automated flux recovery systems that enhance productivity and ensure consistent workflow.
