WHAT IF I TOLD YOU I COULD

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WHAT IF I TOLD YOU I COULD
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WHAT IF I TOLD YOU I COULD

• SAVE YOUR COMPANY HUNDREDS OF THOUSANDS OF
  DOLLARS?

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WHAT IF I TOLD YOU I COULD

• SAVE YOUR COMPANY HUNDREDS OF THOUSANDS OF
  DOLLARS?
• MAKE YOUR COMPANY GREEN?

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WHAT IF I TOLD YOU I COULD

• SAVE YOUR COMPANY HUNDREDS OF THOUSANDS OF
  DOLLARS?
• MAKE YOUR COMPANY GREEN?
• SAVE THE ENVIRONMENT FOR YOUR GRANDCHILDREN?

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AND WHAT IF I TOLD YOU I COULD

• DO IT ALL WITH ZERO INVESTMENT OR CHANGE TO
  YOUR FABRICATION PROCESS?

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WOULD YOU BE INTERESTED?
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The industrialized world is consuming natural
resources at a pace unseen before in human
history
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As we exhaust these resources, the space/land to
store this waste is disappearing equally as
rapidly.
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The EPA is beginning to restrict the disposal of
SAW slag in landfills
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Waste is No Longer Waste
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SUBMERGED ARC WELDING
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SUB ARC WELDING

• The arc is submerged under a blanket of granular
  flux powder
• Electric arc is maintained between a wire
  electrode and the work piece
• The flux granules/powder melt, forming a liquid
  slag which floats on the surface of the weld
  puddle
• After solidification, the slag detaches, leaving
  a clean, smooth weld bead

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SUBMERGED ARC WELDING

• ADVANTAGES
• High Welding Currents
• Deep penetration of weld metal
• High deposition rates of weld metal
• Fast travel speeds
• High quality deposits

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SAW FLUX

• PRIMARY PURPOSE OF FLUX
• Shield the weld metal from the air, preventing
  nitrogen pick-up

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SAW FLUX

• SECONDARY BENEFITS
• Stabilize the arc
• Mechanical support to weld metal
• Shield operator from arc glare
• Limit smoke and fumes

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THREE TYPES OF NEW FLUX POWDER

• BONDED/AGGLOMERATED
• FUSED
• CRUSHED/RECRUSHED

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• BONDED/AGGLOMERATED
• Minerals/Granules dry blended
• Cementing or bonding agent added
• Heated to 300 - 900C forming molten pool
• Cooling into a slag
• Slag is crushed/sized/packaged and sold as new
  flux

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• BONDED/AGGLOMERATED
• Once the oxides are exposed to the electric arc,
  they become fixed and can never again be
  changed
• Just like gold, it can be melted and remelted.

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• FUSED
• Minerals/Granules dry blended
• Added to electric furnace
• Heated to 1500C forming a molten pool
• Cooling into a slag
• Slag is crushed/sized/packaged and sold as new
  flux

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• FUSED
• Once the oxides are exposed to the electric arc,
  they become fixed and can never again be
  changed
• Just like gold, it can be melted and remelted.

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• CRUSHED/RECRUSHED
• Minerals/granules in powder form
• Subjected to the electric arc on the sub arc
  welder
• Heated to 1500C forming a molten pool
• Cooling into a slag
• Slag is crushed/sized/packaged by Titus Flux, and
  sold as new flux

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• CRUSHED/RECRUSHED
• Once the oxides are exposed to the electric arc,
  they become fixed and can never again be
  changed
• Just like gold, it can be melted and remelted.

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CRUSHED SLAG

• As Defined by AWS/ASME
• Crushed slag is classified as NEW FLUX.
• As per AWS - new flux applies to any flux that
  has been blended or crushed, screened and
  packaged, and carries its own markings
• (AWS/ASME A5.23, A5.17, A6)

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Classification of Fluxes

• SAW Fluxes are not classified by the properties
  or chemical composition of the flux itself.
• Classification is based solely on end performance
  (of the wire-flux combination) and the standards
  allow any method of flux manufacture that results
  in compliance with the standard.

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MANUFACTURE OF FLUXES
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BONDED/FUSED CRUSHED SLAG

• When the flux is melted, all the components go
  into solution and form a stable, glass-like
  substance
• The ingredients are completely reacted and are in
  a stable and fixed condition
• No further chemical reaction can take place

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CRUSHED SLAG

• Research proves that crushed slag can be
  reliable, repeatable, and economical
• Published June 1996, AWS Welding Journal
• Tested under AWS D1.1-94/A5.01-87, A5.17-789,
  A5.23-90
• Electrode.Lincoln L-61 (5/32")
• Flux type..Lincoln 860..100 recrushed

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CRUSHED SLAGChemical Analysis
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CRUSHED SLAGMechanical and Radiographic Results
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CRUSHED SLAGImpactCharpy V-Notch
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AWS Code Requirements for Crushed Slag
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INDUSTRIES THAT EMPLOY S.A.W. CRUSHED CLOSED LOOP
FLUX

• A) Steel tanks and Vessels
• Air Tanks
• Air Compressors
• L.P.G. (Liquid Petroleum Gas) Tanks
• Water Tanks (Steel)
• Pressure Vessels
• Fuel Tanks
• Propane Tanks

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INDUSTRIES THAT EMPLOY S.A.W. CRUSHED CLOSED LOOP
FLUX

• B) Roll Rebuilding
• Steel Mill Caster Rebuilding
• Pulp and Paper Roll Rebuilding
• Idler Wheels and Sprockets for Construction
  Equipment (Caterpillar)

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INDUSTRIES THAT EMPLOY S.A.W. CRUSHED CLOSED LOOP
FLUX

• C) Cast Iron Pipe rebuilding Moulds
• D) Pre-Fabricated Metal Buildings
• E) Steel Chimney Liners
• F) Poles and Towers
• Hwy Lighting Towers
• Wind Towers
• G) Piling for Pile Driving
• H) Truck Trailer Frames
• I) Heat Exchangers, Water Panels, Water Ducts

• J) Metal Cladding (Overlay)
• K) Auto Parts (Transmissions, Gears, Crankshafts)
• L) Welded Beams, Overhead Cranes, Wheels
• M) Rail CarsTank Cars, Freight Cars, Locomotives
• N) Electric Turbines and Transformers
• O) Water Dam Gates
• P) Mining and Earth Moving Equipment
• Q) Ship Building

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The advantages of reclaimed flux over virgin
flux are cost, and in some cases, improved
weldability over virgin fluxJ.G.
FeldsteinChairmanASME Committee IX
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TITUS FLUX RECLAIMING

• Reclaiming for 25 years
• USA/Canada/Mexico
• Locations in
• Cartersville, Georgia
• Toronto, Canada
• Subsidiary of Titus Steel Company
• (50 years of service)

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TITUS FLUX RECLAIMING

• Crushing your slag is
• A CLOSED LOOP process as defined by AWS
• Your slag and only your slag
• Your flux and only your flux

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TITUS FLUX RECLAIMING

• Crushing your slag is
• A CLOSED LOOP process as defined by AWS
• Your slag and only your slag
• Your flux and only your flux
• A Partnership
• FABRICATORTITUS FLUX RECLAIMING

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TITUS FLUX RECLAIMING

• The only reason crushed flux will not perform..
• CONTAMINATION

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TITUS FLUX RECLAIMING

• The only reason crushed flux will not perform..
• CONTAMINATION
• Water
• Oil
• Non-metallic material

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TITUS FLUX RECLAIMING

• MANUFACTURING
• State of the art process (identical to
  Lincoln/ESAB)
• High speed CAGE MILL impact crusher
• Homogenous Particles
• Less dust
• More finished product
• Non Hydroscopic

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TITUS FLUX RECLAIMING

• PACKAGING
• 50 lb triple wall bags
• Bins/drums with plastic liners
• 3,000 lb sacks

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TITUS FLUX RECLAIMING

• Partnership
• Plant visit to witness test batch
• Welding problems plant visit
• 1 certified Lincoln SAW welder
• 1 Welding technician (AWS committee member)
• Fabricator visit

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SO. IN SUMMARY

• THE SAVINGS ARE SIGNIFICANT40 70 OF WHAT YOU
  ARE PAYING FOR YOUR FLUX POWDER FROM LINCOLN OR
  ESAB
• ACTUAL SAVINGS LAST YEAR FOR SOME OF OUR
  CUSTOMERS
• TANK MANUFACTURER 35,000
• METAL BUILDING COMPANY 114,000
• TOWER MANUFACTURER 358,000
• RAILWAY TANK CARS 97,000
• PIPE MANUFACTURER 233,000
• ROLL REBUILDER 137,000

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• PLUS
• YOU SAVE ALL YOUR DISPOSAL AND LANDFILL COSTS,
  AND ..
• YOU PRE-EMPT THE EPA BEFORE THEY STOP YOU FROM
  DUMPING SLAG IN THE LOCAL LANDFILL

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• AND FINALLY
• YOU CAN HELP SAVE THE ENVIRONMENT FOR YOUR
  CHILDREN AND GRANDCHILDREN

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SO. I ASKED YOU AT THE BEGINNING OF THIS
PRESENTATION IF YOU WERE INTERESTED IN

• SAVING MONEY
• MAKING YOUR COMPANY GREEN?
• SAVING THE ENVIRONMENT?
• .WITH ABSOLUTELY NO INVESTMENT OR CHANGE TO
  YOUR PROCESS.

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IF YOU ARETHEN LET US DO A

• FREE TEST BATCH
• Save up 250 lbs of slag
• Titus will pick up, process and deliver at no
  cost to you
• Titus representative plant visit to witness the
  test weld
• The proof is in the weld
• Call 1-800-536-5908
• Visit www.titusflux.com
• YOU HAVE NOTHING TO LOSE!

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