Agglomerated SAW Flux Formulation Expert
Budget: ₹12,500 – ₹37,500 INR
I am setting up an in-house line to produce agglomerated submerged arc welding flux and need an experienced specialist to transfer both the formulation and the production know-how to my team.
Target flux type
• Agglomerated flux only—no fused or neutral variants at this stage.
Core ingredients already decided
• Silica and manganese compounds
• Calcium fluoride and suitable binders
• Iron and titanium oxides
Performance goals
The finished flux must run with a high deposition rate and release slag cleanly after welding. Low hydrogen performance would be a welcome bonus but is not compulsory for the first iteration.
I will supply the existing plant layout, mixer, pelletizer, and sintering furnace specs. You will guide any required modifications or new equipment choices, and then provide:
1. Complete batch-level recipe showing exact percentages for each raw material, binder type, moisture range, and any minor additives.
2. Step-by-step processing parameters—from raw material preparation, granulation, drying, and sintering curve (temperature, soak time, cooling rate) to final screening.
3. Quality-control checklist with test methods for grain size, moisture, flux basicity, bulk density, and weld coupon evaluation (deposition rate and slag detachability).
4. A short troubleshooting guide covering common production defects such as friable pellets, excessive fines, or inconsistent slag behaviour.
Acceptance criteria
• Lab-scale sample produced under your instructions passes weld trials that meet AWS A5.x guidelines for deposition efficiency and slag removal.
• Written documentation is clear enough for my operators to replicate the process without further intervention.
Please indicate your relevant production or R&D experience with agglomerated SAW flux, preferred communication schedule, and the earliest date you can begin remote or on-site guidance.
Target flux type
• Agglomerated flux only—no fused or neutral variants at this stage.
Core ingredients already decided
• Silica and manganese compounds
• Calcium fluoride and suitable binders
• Iron and titanium oxides
Performance goals
The finished flux must run with a high deposition rate and release slag cleanly after welding. Low hydrogen performance would be a welcome bonus but is not compulsory for the first iteration.
I will supply the existing plant layout, mixer, pelletizer, and sintering furnace specs. You will guide any required modifications or new equipment choices, and then provide:
1. Complete batch-level recipe showing exact percentages for each raw material, binder type, moisture range, and any minor additives.
2. Step-by-step processing parameters—from raw material preparation, granulation, drying, and sintering curve (temperature, soak time, cooling rate) to final screening.
3. Quality-control checklist with test methods for grain size, moisture, flux basicity, bulk density, and weld coupon evaluation (deposition rate and slag detachability).
4. A short troubleshooting guide covering common production defects such as friable pellets, excessive fines, or inconsistent slag behaviour.
Acceptance criteria
• Lab-scale sample produced under your instructions passes weld trials that meet AWS A5.x guidelines for deposition efficiency and slag removal.
• Written documentation is clear enough for my operators to replicate the process without further intervention.
Please indicate your relevant production or R&D experience with agglomerated SAW flux, preferred communication schedule, and the earliest date you can begin remote or on-site guidance.