Tungsten carbide rod is tungsten carbide cutting tools, which applies different coarse grinding parameters, cutting materials and non-metallic materials. Meanwhile, the tungsten carbide rod can also be applied to a conventional automatic, semi-automatic lathe, and so on. The main process is milling → formula according to the intended use →wet milling →mixing →smashing →drying → sifting → crush → drying → mixed sieved and then drying → mix → granulation suppress → forming → low pressure burning → forming → ??cylindrical grinding fine grinding → packaging →detection size →putting in storage.


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standard rods overview
solid rods
1 central coolant duct - broken link
2 straight coolant ducts
2 coolant ducts 30° helix
2 coolant ducts 40° helix
3 coolant ducts 30° helix
3 coolant ducts 40° helix
micro twisted coolant ducts 

Special Rods

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Welding procedure variables control the welding process and the quality of the welds produced. Joint configuration is determined by the design of the weldment, the metallurgical analysis, and by the process and procedure required by the weldment.

Welding variables are selected after the base metal, filler metal, and joint configuration have been selected. The fixed welding variables include the type of filler metal, electrode type and size, the type of current, and the type of shielding gas.

The adjustable variables control the shape of the weld by affecting things such as bead height, bead width, penetration, and weld integrity. The primary adjustable variables for GTAW are welding current, arc length, and travel speed.

Secondary variables also aid in controlling the welding process, but it is more difficult to calculate the extent of effect. The secondary variables include work and travel angle and the distance the electrode extends beyond the end of the cup.

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Dabbing

The dabber variation is used to precisely place weld metal on thin edges. The automatic process replicates the motions of manual welding by feeding a cold filler wire into the weld area and dabbing (or oscillating) it into the welding arc. It can be used in conjunction with pulsed current, and is used to weld a variety of alloys, including titanium, nickel, and tool steels. Common applications include rebuilding seals in jet engines and building up saw blades, milling cutters, drill bits, and mower blades.

Working the puddle

Another method of adding filler rod is instead of dabbing, to rest the filler rod next to the puddle, and melt it down with the TIG torch. This method is typically high deposition and in some cases, can have an advantage over dabbing. One case where it is superior over dabbing is on thin metal. You can move faster by working the puddle therefore it helps with burn through.

Vacuum welding

For industrial applications, superior results can be achieved by eliminating the effects of absorbed gasses at the weld. This can lead to reduced oxidation, reduced workpiece heat carried by convection and stronger materials due to dissolved or reacted gases such as oxygen, nitrogen and hydrogen.

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Joining tungsten to itself or to other metals should be undertaken with caution and an understanding of the limitations involved. Tungsten can be welded to itself. However, the resulting weldment is always recrystallized and hence brittle. Even the use of a W/Re filler rod does not eliminate the brittleness of the metal adjacent to the heat-affected zone. On the other hand, if a leak-tight high temperature joint is required, welding is the only solution.

For joints that do not have to be leak-tight but require good high temperature mechanical strength, the use of either tungsten or tantalum rivets has proven quite satisfactory. Tantalum rivets, while not as strong as tungsten rivets, are much easier to head. Tungsten rivets take more skill to head, but are the most satisfactory.

If tungsten parts which are not to be exposed to very high temperatures are to be joined, brazing is preferred to welding. As long as the braze material has a melting point below the recrystallization temperature of tungsten (under 2200 °F), embrittlement can be avoided. Copper or silver alloys containing small proportions of nickel or iron are suitable for these applications.

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Tungsten can be machined by turning, milling, or drilling. For thick-walled parts, slight preheating of the work to 400 °F is sometimes helpful; otherwise highly chlorinated oil such as trichloroethylene is used. Using a C-2 Type Carbide Tool, a suggested Geometry is:

• Side Angel: 10°
• End Cutting Edge Angle: 3° to 10°
• Back Rake: 0°
• Clearance: 3° to 5°
• Nose Radius: 1/32" to 1/16" Radius
• Cutting Speed: 100 to 200 RPM

The final shaping of tungsten parts is frequently done by grinding. Silicon carbide wheels with a hardness of J to L and a grain size of 100 to 120 have proven useful for most applications. Since tungsten is hard and brittle, surface checking can be a problem unless adequate cooling is used. An oil emulsion type coolant is recommended.

Inverters Add Key Benefits:

A quick review is in order. About 30 years ago, Miller Electric invented and patented the squarewave AC output and adjustable balance control function found in its line of Syncrowave® TIG welders. This technology made the transition through the zero amperage range faster than a regular sine wave, which improved arc starts and created a more stable arc. With balance control, the operator could change the duration of the AC half cycle, adjusting the electrode negative (EN) from 32 up to 68 percent.

Today, the next generation of this technology - AC TIG inverter - features three advanced squarewave technology capabilities.

First: The AC TIG inverter produces incredibly smooth, stable arcs because the squarewave is driven through the zero point thousands of times faster than a rectifier-based welder. Miller's Dynasty® inverters are so fast that its built-in, high frequency capabilities are used for arc starting only. They also offer Lift-Arc™ starting capabilities to eliminate the use of high frequency completely, even on AC.

Second: Inverter-based welders extend EN balance control. The Dynasty lets operators fine-tune duration times from 50 percent to 90 percent. Making the EN portion of cycle last longer achieves greater penetration; narrows the weld bead; increases travel speeds up to 20 percent; may permit using a smaller diameter tungsten to more precisely direct the heat or make a narrower weld bead; and, reduces the size of the etched zone for improved cosmetics.

Third: Inverter-based welders let operators adjust the welding output frequency, from 20 to 250 Hz in the case of the Dynasty. Conventional welders have a fixed output of 60 Hz. Lowering the frequency produces a broader arc cone, widening the weld bead profile, which is great for build-up work. Increasing frequency above 60 Hz produces a tight, focused arc cone. This pinpoint heat control drives more heat into the weldment for better penetration and a narrower weld bead, which helps when welding in corners, on root passes and fillet welds or anywhere precision welding is required.

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For as long as anyone can remember, the prevailing wisdom was that in order to get the best results, anyone who was TIG welding aluminum, magnesium or other alloys that required an AC arc had to use a pure tungsten electrode.

But not anymore. For the last five years the industry has made a dramatic shift toward inverter-based AC TIG welders that incorporate advanced squarewave technology to improve weld quality, increase travel speed and reduce operating costs.

However, in order to gain the maximum benefits from inverter technology, selecting the right tungsten now becomes an increasingly more critical issue. In the past, pure tungsten was the only choice for AC TIG welding. But that's no longer the case with the latest inverter technology. Today, industry experts recommend against pure tungsten in favor of the new "rare earth" tungstens. By adding elements such as cerium or lanthanum these electrodes outperform pure tungsten.

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1. Preparatory work
(1) be familiar with the pattern and process planning, master of the location, size and requirements of the welding, a reasonable choice of welding method and order.
(2) clean up the workplace, aids and protective equipment.
(3) Check the equipment. The adjusting mechanism on the welder, wire, cable and grounding is good; handle insulation is good, the ground wire and the workpiece connection is reliable; by sea, air, road is smooth; high frequency or pulsed arc initiation and stability whether good.
(4) Check the workpiece. Slag, dirt, grease, sand and other objects may not exist in the groove weld both sides of the 20mm range, not oil, rust, welding wire for degreasing rust.
(5) do not place in the outlet or forced ventilation welding.
(6) According to the process documentation and product design requirements, the correct choice of welding wire.

2. Security technology
(1) the wearing of personal protective equipment, work in well-ventilated environment, the workplace to prevent humid and filled with water, is strictly prohibited stacked flammable liquids.
(2) of the workpiece must be reliably grounded when welding with DC power, attention to reducing the operating time of the high-frequency electric arc to cut off the high frequency power supply.
(3) welding must use compressed air to the water in the entire waterway system blowing, in order to avoid frozen pipes.
(4) grinding tungsten to wear gloves and masks.

3. Process parameter selection
Gas tungsten arc welding process parameters are mainly the type and polarity of the welding current, welding current, tungsten diameter and shape of the ends to protect the gas flow.
(1) Welding current type and size generally select the current type of workpiece material. The size of the welding current is the most important parameters to determine the weld penetration depth, it is mainly based on workpiece material, thickness, joint type, welding position to choose, and sometimes also consider the factors of welders technical level (manual welding).
(2) The shape of the tungsten diameter and ends tungsten electrode diameter according to the welding current size of the current polarity selection (see Table 3-14).
Tungsten extreme head shape is an important process parameters. According to the type of welding current is used, the choice of a different shape of the ends, as shown in Figure 3-11 shows, the state-of-the-art point of view. The size of the tungsten allowable current, arc starting and arc stability, Table 3-15 lists the recommended current range of state-of-the-art size tungsten different.
(3) gas flow rate and nozzle diameter welding quality depends largely on the protective effect of argon. Under certain conditions, the gas flow rate and nozzle diameter of one of the best range, at this time, gas protection is best, effective protected areas. Table 3-16 shows the welding current and nozzle diameter, gas flow relationship.
Argon protective effect of the assessment is mainly based on the color of the weld surface. Welding the protective effect of surface color and gas are shown in Table 3-17.

4. Operating techniques
TIG operating techniques, including arc, filler wire welding, the closing arc process.
(1) arc
① short circuit arc method (contact arc method), tungsten, weldments instantaneous short-circuit, immediately a little mention, the arc between the weldment and tungsten;
② frequency arc method, the use of high-frequency arc starter ordinary frequency alternating current (220V or 380V, 50Hz) to convert the high-frequency (150 ~ a 260kHz), high pressure (2000 ~ 3000V), the argon gas breakdown ionizing , in order to ignite the arc.
(2) closing arc
(1) increase the welding speed method, welding torch, welding will be terminated gradually increase the speed of mobile;
(2) current decay welding termination, stop the filler wire welding current is gradually reduced, so that the molten pool size is shrinking, the last power outage, the welding gun or torch to stop walking.
(3) filler wire welding with filler wire must wait before they can fill in the parent metal melted fully added in order to avoid lack of fusion, filling the position to fill the bath cutting-edge site, and wire to recover, try not to immediately out of the argon gas protected areas.

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The TIG harmful factors
Argon arc welding affect the body of harmful factors in three areas:
1, radioactive
Thorium tungsten thorium is a radioactive element, thorium tungsten tungsten arc welding radiation dose is very small, within the allowable range, there is little risk. If the radioactive gases or particles into the body as within the radioactive source, it will seriously affect their health.
2, high-frequency electromagnetic field
Using high-frequency arc, the high-frequency electromagnetic field strength between 60 ~ 110V / m, more than the health standard (20V / m) several times. But since time is very short, has little effect on the human body. Frequent starting arc, or the continued use of the high-frequency oscillator as a stable arc device in the welding process, the high-frequency electromagnetic fields can become one of the harmful factors.
3, the harmful gases - ozone and nitrogen oxides
Argon arc, the arc column temperature. UV radiation is much larger than the general arc welding in the welding process to produce large amounts of ozone and nitrogen oxides; In particular, the ozone concentration is far above the reference health standard. If you do not take effective ventilation, these gases impact on human health, argon arc welding the main harmful factors.
Second, the security measures
1, ventilation measures
Argon arc welding work site should have good ventilation, the discharge of harmful gases and dust. In addition to the plant ventilation, welding capacity, welder concentration install several axial flow fan out the exhaust.
In addition, measures can be applied to local exhaust ventilation will arc around the harmful gases siphoned, such as open arc exhaust hood, exhaust gas torch, light a small fan.
Protective ray measures
Maximize the use of very low radiation dose of cerium tungsten. Thorium-tungsten and cerium tungsten processing, should be sealed or exhaust the grinding wheel, the operator should wear personal protective equipment such as masks, gloves, face and hands should be washed after processing. Thorium tungsten and cerium tungsten pole should be placed on aluminum box within save.
3, high-frequency protection measures
Preparedness and weaken the influence of high frequency electromagnetic fields, the measures taken are:
(1) The workpiece is well grounded, the torch cable and ground use metal braided wire shield;
(2) the appropriate lower frequency;
(3) Try not to use high-frequency oscillator as a stable arc device, reducing the duration of action of high frequency electricity.
(4) other personal protective measures
Argon arc when, due to ozone and ultraviolet rays are strongly advised to wear non-cotton clothes (such as acid, tussah silk, etc.). Welding inside the container can not use local exhaust ventilation, air helmet and air mask or anti-virus masks and other personal protective measures.
 

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