2. 1. 1 electrode
At present, there are about 500 production enterprises in covered electrode, including nearly 300 enterprises with perfect production conditions, testing means and reasonable quality assurance system, and nearly 200 enterprises with certain production conditions but lacking testing means. The production capacity of the whole industry exceeds 6.5438+0.5 million tons, far exceeding the market demand. Covered electrode's production enterprises are distributed in all areas except Tibet, belonging to machinery, metallurgy, energy, shipbuilding, agriculture and other departments. The economic types are state-owned, collective, private, joint venture, sole proprietorship and shareholding system.
After the peak period of 1992 ~ 1993, due to the rapid increase of production enterprises, the production capacity and output of covered electrode industries increased rapidly, which led to the continuous decline of the prices of ordinary products and the sharp reduction of the profit margin in covered electrode to unprofitable or loss. At present, except for a few enterprises with large scale, multi-industry development and special covered electrode (low hydrogen covered electrode, stainless steel covered electrode, surfacing covered electrode, nickel-based covered electrode, cast iron welding rod and other special covered electrode), most other enterprises are in a state of capital preservation or loss. The production of ordinary carbon steel covered electrode is increasingly concentrated in several large-scale welding material manufacturers, such as Tianjin Jinqiao Welding Material Company, Tianjin Bridge Group Company, Sichuan Atlantic Group Company, Shanghai Welding Equipment Co., Ltd. and Jiangsu Universe Group Company.
Faced with fierce market competition, small and medium-sized enterprises are actively reducing the cost of raw and auxiliary materials and energy consumption in order to maintain their operations, resulting in a certain decline in product quality of some enterprises. Large-scale enterprises not only reduce the production cost in covered electrode by means of scale operation, strengthening management and improving technical level, but also actively adjust product structure, develop welding wire, flux or other industries, improve market competitiveness and actively explore foreign markets.
2. 1.2 welding wire
(1) gas shielded solid core welding wire
At present, there are more than 50 gas shielded solid-core welding wire manufacturers/kloc-0 in China, and nearly 50 sets of production equipment have been imported from Germany, Sweden, Canada, Japan, Switzerland, Italy and Taiwan Province Province of China, with a total investment of more than 50 million US dollars. Domestic or self-developed equipment exceeds 100, and the production capacity exceeds 200,000 tons, mainly produced by state-owned, collective, private and joint ventures. Other large-scale covered electrode production plants have gradually become the backbone enterprises of welding wire production. In the past five years, most enterprises have made breakthroughs in key technologies, so all production enterprises are increasing the production equipment and output of gas shielded welding wires. However, due to the influence of metallurgy, there are few varieties of gas shielded welding wire, except for the larger output of ER49- 1 and ER50-6, most of the other varieties have smaller output.
(2) Gas shielded flux-cored wire
In the past five years, the production of flux-cored wire has made great progress, from more than 500 tons in 1996 to more than 4000 tons in 2000. At present, there are 28 production enterprises (including 3 foreign-funded enterprises) and 38 production lines. Among them, there are 20 imported production lines and 8 self-made production lines 18, and the production capacity of existing equipment has reached more than 20,000 tons. At present, there are 3-4 enterprises with an annual output of more than 500 tons, and most of the production equipment is idle or unable to play its due role.
(3) Submerged arc welding wire
At present, there are hundreds of enterprises that can supply submerged arc welding wires, and some enterprises can supply them in the form of disks. Because submerged arc welding technology has been improved to the specifications of multi-electrode and welding wire except single electrode, the application of submerged arc welding wire is increasing year by year, and the number of copper-plated submerged arc welding wire is increasing in recent years.
2. 1.3 flux
There are more than 30 flux manufacturers in China, and the annual production capacity of the whole flux industry is about 6.5438+0.5 million tons, including 654.38+0.65438+0 ~ 6.5438+0.2 million tons of molten flux and 30 ~ 4 million tons of sintered flux. At present, there are more than ten enterprises that can produce sintered flux. In recent years, the market of sintered flux has been expanding, and the proportion of sintered flux in flux has been increasing.
2. 1.4 solder
Brazing materials belong to non-ferrous metal industry. At present, there are more than 300 brazing material manufacturers in China. Among them, there are more than 60 solder production enterprises, most of which are collective, private and private enterprises, except for a few belonging to metallurgy, machinery, China People's Bank and nonferrous metals corporation. More than 600 kinds of solders have been produced. The output of various solders has reached 40,000 ~ 50,000 tons, and the application of brazing materials has spread throughout all walks of life. With the continuous development of household appliances industry, microelectronics industry and information industry, the development of brazing materials is facing new development opportunities.
2.2 Output Statistics of Welding Materials Industry in Recent Five Years (1996 ~ 2000)
1996 to 2000, the annual output statistics of various materials in welding materials industry are shown in table 2-1-kloc-0/,the export statistics are shown in table 2- 1-2, the sales statistics are shown in table 2- 1-3, and the variety changes of various welding materials are shown in table 2-3.
Table 2-2- 1 Output (unit: 10,000 tons)
age
product
1996
1997
1998
1999
2000
welding electrode
60
Seventy two
82
88
90
Solder wire
gas shielded welding
7.2
8.2
9.3
10.4
1 1.6
submerged-arc welding
3. 1
3.3
3.6
4. 1
4.7
flux
4.6
5.0
5.4
6.2
7. 1
brazing filler metal
1.6
2.0
2.6
3.4
4.4
Combination plan
76.6
90.5
102.9
1 12. 1
1 17.8
Table 2-2-2 Export Volume (Unit: 10,000 tons)
age
product
1996
1997
1998
1999
2000
welding rod
7.4
8. 1
8.9
9.7
10.4
Welding wire (total)
1.4
1.6
1.9
2. 1
2.4
traffic
0.8
0.9
0.8
1.0
1.2
total
9.6
10.6
1 1.6
12.8
14.0
Table 2-2-3 Sales (Unit: 100 million yuan)
age
product
1996
1997
1998
1999
2000
welding rod
30.6
35.2
39.8
4 1.7
42.4
Welding wire (total)
7.0
7.4
7.9
8.3
8.8
traffic
1.4
1.5
1.6
1.7
1.8
total
39
44. 1
49.3
5 1.7
53
Table 2-2-4 Variety Quantity (unit: one)
age
product
1996
1997
1998
1999
2000
welding rod
320
368
380
390
celebrity
Solder wire
75
84
90
95
100
traffic
50
60
70
80
90
total
100
180
300
450
600
2.3 Joint venture, cooperation and technology introduction of welding materials industry
1996 ~ 2000, the technology import of welding material industry was mainly in welding wire industry (including solid wire and flux-cored wire). Covered electrode imports only 320 tons of hydraulic press and low-temperature continuous oven imported from Germany by Sichuan Atlantic Welding Materials Co., Ltd. and E308L- 16, E347- 16 and EZNi- 1 covered electrode technologies imported from Taiwan Province Province. See table 2-3- 1 for technical introduction. The big change in the industry is that Jintai Metal Industry Company managed Jiangsu Universe Welding Material Company after acquiring the original Jining covered electrode Factory.
Domestic school-enterprise cooperation includes Beijing Golden Sun Flux-cored Wire Co., Ltd. established by Beijing University of Technology and former Beijing Welding Material Factory. It is common for domestic universities, research institutes and production enterprises to cooperate on a certain project (product). See table 2-3-2 for the sole proprietorship, joint venture and cooperative enterprise.
Table 2-3- 1 Technology Import
serial number
Lead-in unit
Imported content
Introduce the country
time
Import quantity
1
Tangshan Xinda welding material company
Copper plating and winding equipment
Germany
1996
1
2
Hubei xianda welding material company
Copper plating and winding
Germany
1996
1
Flux-cored wire equipment+software (2)
Germany
1996
1
three
Guangzhou witters co., ltd
Flux-cored wire equipment
Japan
1996
1
four
Zhejiang Jiaxing Oriental Welding Industry Co., Ltd.
Flux-cored wire equipment+software (3)
Japan
1996
1
five
Shandong Zibo lefei welding material company
Flux-cored wire equipment+software (3)
Italy
1999
1
six
Beijing antai technology co., ltd.
Flux-cored wire+software (3)
Japan
2000
1.5
seven
Sichuan Atlantic welding material stock company
Covered electrode production line+low temperature oven
Germany
1998
1
Copper-plated welding wire
Japanese Taiwan Province Province.
1997
1
E308L- 16，
E347- 16, EZNi- 1 covered electrode technology.
Taiwan Province Province, China
1997
Table 2-3-2 Joint ventures and cooperative enterprises
Enterprise name
Joint venture (partner)
approaches to cooperation
scope of business
Jining ruitai metal industrial company
Taiwan Province of China
sole proprietorship
welding electrode
Zigong Atlantic welding wire company
Taiwan Province province, China.
joint investment
Carbon dioxide gas shielded welding wire
Tiantai welding material (Kunshan) company
Taiwan Province of China
sole proprietorship
flux-cored wire
Beijing Lian Gang welding material company
Hong Kong, China
joint investment
flux-cored wire
Shandong Zibo lefei welding material company
Hong Kong, China
joint investment
flux-cored wire
Beijing goldsun flux-cored wire company
Former Beijing welding material factory
Beijing University of Technology
cooperate
flux-cored wire
Ha Qian Han Liao co., ltd
Harbin Nonferrous Metals Smelter
Harbin welding research institute
cooperate
brazing filler metal
2.4 New varieties and research and development
In recent years, various manufacturers have developed many special welding materials for hydropower, nuclear power, bridge engineering and national defense and military products, including covered electrode, welding wire, flux and solder.
The new products and R&D of coated covered electrode mainly focus on low-hydrogen coated covered electrode and stainless steel coated covered electrode, especially the high-strength ultra-low-hydrogen coated covered electrode for military and nuclear power. Taiyuan University of Technology Welding Materials Research Institute won the second prize of National Science and Technology Progress Award in 2000 because of its research achievements in stainless steel covered electrode products and related technologies for many years.
The research and development of welding wire industry is mainly the formula technology and processing and manufacturing technology of flux-cored wire. Beijing Lian Gang Company relies on the technical strength of Iron and Steel Research Institute, and Tianjin Sanying Company relies on the research strength of Tianjin University, and its work in this field is outstanding.
In recent years, the research and development of flux industry mainly focuses on the development of new varieties of sintered flux. Sintered fluxes developed for hydrogenation reactors, nuclear power and thermal power projects and for the manufacture of steel pipes in pipeline laying have been applied.
In recent years, the research and development activities of solder industry are the most active. The number of R&D solder research institutions and manufacturers is increasing year by year, and the research papers are increasing year by year, and the level of papers is constantly improving. Great progress has been made in the research and application of silver-free, low-silver solder, low-tin solder and lead-free solder, and new breakthroughs have been made in the processing and molding technology of solder. Many achievements have been made in the research and production of solder paste.
2.5 Industry development trend
From 1996 to the development of various materials in the welding material industry in 2000, it can be seen that more and more materials adapt to the development of welding production in the direction of high efficiency, high quality, low cost and automation, and brazing materials adapt to the development of electronic technology are also developing rapidly, while ordinary covered electrode products have gradually declined from the peak of output, and the expansion of low price has reached the limit. Based on the comprehensive market trend, the future development trend of welding material industry during the Tenth Five-Year Plan period is as follows:
2.5. 1 electrode
As the low-price output expansion of ordinary covered electrode has reached the limit, the output of this kind of covered electrode will gradually shrink in the future, and the corresponding product structure of covered electrode will be adjusted, and the proportion of special covered electrode (referring to low hydrogen, heat-resistant steel, stainless steel, nickel-based and surfacing covered electrode, etc.). ) will increase, the total amount of coated covered electrode will decrease, and the proportion of coated covered electrode in the whole welding material will decrease, gradually decreasing to 65% or lower.
solder wire
(1) gas shielded solid core welding wire
Although there are few kinds of gas shielded solid-core welding wires at present, the main products available to the market are ER49- 1 and ER50-6, but their demand and output are increasing year by year, and their output will gradually rise to about 20% of the whole welding materials.
(2) Flux-cored wire
The output of flux-cored wire has a high growth rate from 1996 to 2000. At present, the largest domestic output is gas shielded carbon steel flux-cored wire, and the variety of flux-cored wire will increase rapidly in the future. Welding wires for low-temperature steel, weather-resistant steel, heat-resistant steel, seawater corrosion-resistant steel and high-strength structural steel, which cannot be provided by solid-core welding wires, will be filled by flux-cored welding wire products. In addition, self-shielded flux-cored wire for oil and gas pipeline welding and surfacing flux-cored wire for surface repair in various industries will also develop continuously, so during the Tenth Five-Year Plan period, flux-cored wire will develop greatly, and its proportion in all welding materials will increase to about 3%.
(3) Submerged arc welding wire
The proportion of submerged arc welding wire will not change greatly, and China will keep the proportion of 10% ~ 13%.
flux
Like submerged arc welding wire, the total output of submerged arc welding agent will remain within a certain range, and there will be no big increase, but the structure of submerged arc welding agent will change to some extent. During the Tenth Five-Year Plan period, in the total flux of submerged arc welding, the proportion of sintered flux will increase, while the proportion of melted flux will decrease.
solder
Due to the rapid development of household appliances industry, microelectronics industry and information industry, the demand for brazing materials is also increasing, and new brazing products adapted to the development of new technologies will be continuously developed. During the Tenth Five-Year Plan period, the output of brazing materials will account for 6% of the total output of welding materials.