Production Equipment
 
　　1) To ensure the accuracy of the formulas for high-performance special welding rods, sintered fluxes, and cored wires, some foreign welding material companies have established modern raw material pretreatment systems, including raw material inspection, screening, and large-scale dry mixing to ensure precise and uniform composition, as well as baking and pre-sintering treatment of some raw materials.
 
 
　　2) Foreign countries have adopted low-noise, high-speed wire-cutting machines to replace the existing high-noise, low-speed wire-cutting machines, improving the wire-cutting environment and wire-cutting quality.
 
 
　　3) Foreign countries have increased the coating pressure of oil-pressure welding rod coating machines, reducing the amount of water glass added, making the welding rod coating denser and smoother. Sichuan Daxiyang Company has introduced an oil-pressure coating machine with a total pressure of 320t, equipped with a continuous low-temperature and high-temperature drying oven, achieving an annual output of more than 10,000 tons of high-quality low-hydrogen welding rods on a single production line. Referencing the imported equipment, Changzhou Hengchuang Machinery Company developed a new 250t oil-pressure coating machine, which can normally coat welding rods under a gauge pressure of 200～240kgs/c㎡, while most domestic welding material companies use a 200t oil-pressure coating machine that can only normally coat welding rods under a gauge pressure of 120～160kgs/c㎡.
 
 
　　4) The copper plating speed of foreign 20～24-wire unfolded copper-plated welding wire production lines has exceeded 360 meters/minute, while domestic speeds are mostly 180～300 meters/minute. Especially to adapt to the production of various types of welding wires, they have adopted a continuous single-wire production line from rough drawing, fine drawing to copper plating, with an operating speed of 700～800 meters/minute, resulting in high production efficiency and convenient for changing welding wire types. Moreover, on this single-wire continuous production line, it is easy to switch between the production of copper-plated and unplated (special coating) welding wires.
 
 
　　5) Foreign countries have adopted a factory closed dust removal and ventilation method for the production of melting fluxes, while domestic production is still open-air, with billowing smoke and dust, causing significant environmental pollution.
 
 
　　6) Foreign countries all use advanced automated equipment for the production of sintered fluxes. In China, only Jinzhou Tian’e Welding Materials Company has introduced advanced foreign equipment; other sintered flux production plants mostly use domestically produced or self-made equipment. Mixers and granulation equipment vary widely, and sintering furnaces are not standardized, resulting in poor flux shaping and poor particle strength.
 
 
　　7) Foreign countries have adopted advanced welding material packaging equipment, making the packaging of finished welding materials beautiful and moisture-proof, while the packaging of welding materials from most domestic companies varies greatly.
 
 
　　Detection Methods
 
　　Direct-reading spectrometer: Only simple crystallization treatment is needed on the metal surface of the sample, and the chemical composition can be immediately measured by the instrument. It can quickly determine the chemical composition of incoming steel coils, steel wires, and steel strips by sampling each bundle to prevent mixing and eliminate unqualified products. It can randomly sample welding material products on the production line and measure the chemical composition of the weld metal during welding.
 
 
　　X-ray fluorescence spectrometer: It can analyze the components of various mineral raw materials and analyze the components of welding rod coatings, fluxes, and cored wire cores. Foreign well-known welding material companies use X-ray fluorescence spectrometers to directly monitor the stability of the formulas during production. The operating procedure is to use an X-ray fluorescence spectrometer to produce standard spectral maps for the accurate formula of each welding rod, flux, and core. During production, samples of the uniformly mixed welding rod coating powder, the filler powder of the cored wire, and the flux during the production process are analyzed using an X-ray fluorescence spectrometer to immediately measure their spectral maps. Then, these are compared with the standard spectral maps. If the spectral maps are within the normal deviation range, production can continue normally. If the spectral maps exceed the normal range, production should be stopped immediately to check whether unqualified raw materials were mixed in, or if the proportions were incorrect, allowing timely correction of the erroneous formula.
 
 
　　Metallographic microscope: For different types of high-quality welding materials, it monitors whether the microstructure of the weld metal meets the requirements under normal welding parameters. In addition, the production of micro-alloyed high-purity welding materials should be equipped with a metal oxygen and nitrogen analyzer; the production of high-performance heat-resistant steel welding materials should be equipped with a high-temperature tensile testing machine; and the production of low-temperature welding steel materials below -780°C (below the freezing point of CO2 dry ice) should also be equipped with corresponding low-temperature impact testing equipment.
 
 
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