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POLYVAC 2000 Optical Emission Spectrometer, manufactured by Hilger Analytical Ltd., U.K., is one of the most technologically advanced spectrometers. It incorporates a microprocessor based control and measuring system. The Spectrometer and its attendant source unit have been designed for operation under full computer control. Various programmes are available for low alloy steels, tool steels, stainless steels, cast irons etc. The Spectrometer enables to achieve accurate and prompt chemical analysis of weld metals, base materials and wire rods with remarkable saving in testing times. In turn, it helps expedite product developmental and research activities.

Gas Chromatograph
Gas Chromatograph is used for determination of diffusible hydrogen in weld metals. It is a fast and accurate technique for detection of components of a gas mixture. Analysis is based on the relationship between the peak parameters of height and area and the concentration of the component in the sample mixture. To utilize peak area measurement efficiently for quantitative analysis, a calibration curve is constructed by using known components as a standard. Analysis is then made by employing the calibration curve in conjunction with peak area calculation. Time taken, in determining hydrogen by this equipment is only 6 hours against the mercury method which takes 72 hours.

Couloscope is used to measure metallic coating thicknesses accurately and reliably which cannot be done by non-destructive methods. In Couloscope, deplating process is carried out in a measuring cell. The quantity of electricity required to remove a coating is directly proportional to the mass of the metal to be removed, so that if the deplating current and deplated area are kept constant, the deplating time is directly related to the coating thickness. When the coating is completely removed and the substrate material underneath it is exposed, the cell voltage changes abruptly. This effect is used in the Couloscope to automatically terminate the deplating process. This instrument is being used to measure copper coating thickness on CO2 welding wires.

Concentricity Tester
Concentricity tester, ZTM004, measures the eccentricity of electrodes by non-destructive method. The eccentricity of an electrode under examination is directly displayed on a dial. If the adjustable tolerance limit is exceeded, a pilot lamp illuminates and an acoustic signal is heard. The instrument is so sensitive that virtually any electrode, upto 12 mm diameter, which is suited to the magnetic field principle, can be tested in units of 0.01mm whereby fractions of these graduations can still be read off quite easily. The instrument is calibrated with the help of standard calibration electrodes prior to use.

Ultra-x is used for rapid determination of moisture present in the electrodes covering. The principle of drying by infra-red radiation with simultaneous weighing is the special feature of this instrument. The magnetically damped weighing system is designed to eliminate the effect of heat radiation. Scale is graduated to direct percentage readings. Rutile and Cellulosic electrodes, which are baked upto 170oC, are checked for moisture content by Ultra-x.

Humidifier is used to study the effect of atmospheric moisture on electrodes' covering after different exposure periods. With different exposure period and humidity level, coating moisture of the electrodes and hydrogen percentage in the weld metal is being checked in hydrogen controlled electrodes. This data is useful for various customers, specifically those located in coastal areas.