The production of welding consumables in my country has generally increased in step with steel, and the output has continued to increase in recent years. Only counting electrodes and wires, the output was 629,600 tons in 1996, 1.449 million tons in 2002, and 1.7 million tons in 2003 (including 1.2 million tons of electrodes, 300,000 tons of solid wires, 35,000 tons of flux-cored wires, submerged arc Welding wire flux 200,000 tons), is the world's largest welding material production and consumption country. 

However, the output of manual welding electrodes in the welding consumables produced in my country has always accounted for about 75%, and the total amount of various welding wires is about 25%. Calculated on the basis of deposited metal, in 2002, the welding mechanization and automation rate in my country could only reach 40.1%, while the industrial developed countries in the world are generally above 60%-70%. It can be seen that the automation rate of welding production in my country is still relatively low in general. The gap between my country's welding consumables industry and industrialized countries is no longer in terms of output, but in terms of overall quality and scientific research level, including personnel quality, management level, production equipment, testing technology, product development and so on.

1. Welding rod

At present, there are about 500 welding electrode manufacturers in my country, of which about 300 have perfect production conditions, testing methods and a reasonable quality assurance system, and nearly 200 have certain production conditions but lack testing methods. The industry's production capacity is about 150 Million tons. In 2003, the output of welding rod was 1.2 million tons.

Welding electrode manufacturers are located in all regions except Tibet, and their economic types include state-owned, collective, private, joint venture, sole proprietorship, and shareholding. Welding rods are produced in several large welding consumables manufacturers, such as Tianjin Jinqiao Welding Materials Company, Tianjin Bridge Group Company, Sichuan Atlantic Group Company, etc. The varieties are mainly structural steel electrodes, as well as heat-resistant steel electrodes, stainless steel electrodes, surfacing electrodes, nickel-based electrodes, cast iron electrodes and other special-purpose electrodes.

2. Welding wire

2.1, gas shielded solid core welding wire

At present, there are 200-250 gas-shielded solid welding wire manufacturers in the country, and nearly 50 sets of various production equipment have been imported from Germany, Sweden, Canada, Japan, Switzerland, Italy and Taiwan, and more than 100 domestic or self-developed equipment. The annual production capacity is close to 600-700,000 tons. In 2003, the output of solid welding wire was 300,000 tons.

Solid core welding wire production enterprises are mainly composed of state-owned, collective, private, joint venture and sole proprietorship. Other large-scale welding electrode production plants have gradually become the backbone of welding wire production. The larger production plants include Jinzhou Jintai Metal Industry Co., Ltd., Sichuan Atlantic Welding Wire Products Co., Ltd., etc. However, there are fewer varieties of gas shielded welding wire. Except for ER49-1 and ER50-6 models, which have a larger production volume, most of the other varieties have a small output.

2.2. Gas shielded flux-cored welding wire

Advanced flux-cored welding wire, due to its unique process performance, has become the fastest growing welding consumable in my country, from less than 1,000 tons (mainly thick wire) in 1996 to 35,000 tons (mainly thin wire) in 2003 , Developing at an average annual growth rate of more than 50%. In the past, it mainly relied on imports. Now more than 50% of the flux-cored welding wire used in China is produced by itself, and there is a small amount of export. The application fields have gradually expanded from shipbuilding to construction, bridges, heavy machinery, boilers, pressure vessels, pipelines, steel structures and other industries.

There are 29 manufacturers of flux-cored welding wire nationwide and 49 production lines, including 25 imported production lines (including 3 made in Taiwan) and 24 domestically produced, with an annual production capacity of more than 50,000 tons. There are 4 large-scale flux-cored wire production plants in China, namely Tiantai Welding Materials (Kunshan) Co., Ltd., Guangtai Welding Materials Co., Ltd., Tianjin Sanying Welding Industry Co., Ltd., and Antai Technology Co., Ltd. Welding Materials Division Company (Beijing Ganglian Welding Materials Co., Ltd. merged into this company in 2003).

At present, my country's flux-cored welding wire products mainly include three series of titanium gas protection, alkaline gas protection and wear-resistant surfacing. They are suitable for carbon steel, low-alloy high-strength steel, stainless steel, etc., and can meet the welding requirements of general engineering structures.

2.3. Submerged arc welding wire and flux

The output of submerged arc welding wire has also increased significantly in recent years, but it only accounts for about 5.5% of the total welding consumables. The proportion of submerged arc welding wire in industrially developed countries is generally between 8-10%.

Since the production of submerged arc welding wire is relatively simple, both general electrode factories and steel wire factories can supply it. There are hundreds of companies that can provide submerged arc welding wire, and some companies supply it in disk form. The output in 2003 was about 80,000 tons.

There are mainly two types of submerged arc fluxes, smelting type and sintered type. Our country mainly produces and uses smelted flux. At present, there are more than 30 flux production companies with an annual production capacity of about 150,000 tons, of which smelted flux is 110,200,000 tons, and sintered flux is 30,000 to 40,000 tons. There are more than 10 companies capable of producing sintered flux. In recent years, the sintered flux market With continuous expansion, the proportion of sintered flux in the flux is also increasing. In 2003, the output of submerged arc flux was about 120,000 tons.

3. There are problems

⑴ The domestic market price of welding consumables is too low, especially the price of welding rod is too low, causing a vicious circle;

⑵ There are few special products, such as low-smoke welding rods used for sealing sites, welding rods with strong anti-porosity ability coated with anti-rust layer, etc.;

(3) The variety of solid-core welding wire is small, which is mainly limited by the supply of steel.

Link to this article： The status quo and existing problems of the welding industry

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