ASUN-80 High-Carbon Steel Wire Automatic Slag Scraping Resistance Butt Welder

1. Customer Background and Challenges

SEVERSTAL is a leading Russian steel company, primarily involved in the development, production, and sale of various steel coils, wire rods, and specialty steels, occupying 50% of the domestic wire rod market in Russia. Initially using imported European butt welders and regular butt welders, they faced issues due to sanctions needing a high-end butt welder supplier. The existing machines had the following problems:

• Low Quality: Non-automated control resulted in a low pass rate after welding.
• Easy to Break: Manual grinding led to excessive labor and a high risk of breakage during tying.
• Lack of Maintenance: European suppliers stopped providing maintenance due to sanctions.

2. High Customer Requirements

In February 2023, SEVERSTAL contacted us through online information and discussed their requirements for a custom welder:

1. Ensure effective welding strength with 0.9% carbon content and a 99% pass rate.
2. Equip the machine with devices to solve all quality-impacting factors.
3. Include a full parameter tracking control system: pressure, time, current, temperature, displacement.
4. Achieve high welding efficiency with welding and slag scraping completed within one minute.
5. Handle various workpiece specifications from 8mm to 16mm diameter.

3. Optimizing to Meet Customer Requirements

Combining customer requirements with our years of R&D results, Anjia’s business, R&D, welding technology, and project departments conducted a new project development meeting. We discussed processes, fixtures, structures, power supply methods, and configurations, identified key risk points, and developed solutions.

The new generation automatic slag scraping resistance butt welder utilizes resistance heating for perfect welding of high-carbon steel wires without slag inclusion or porosity, meeting tensile strength requirements.

4. Customer Satisfaction and Recognition

After confirming the technical agreement and signing the contract, Agera‘s departments immediately initiated the project, setting timelines for design, processing, procurement, assembly, and customer pre-acceptance. Through the ERP system, we coordinated and monitored the progress, ensuring high-quality delivery.

After 60 working days, SEVERSTAL’s custom high-carbon steel wire automatic slag scraping butt welder completed the aging test. Our professional after-sales engineers traveled to Russia for installation, commissioning, and training. The equipment met all customer acceptance standards, achieving high product yield, improved welding efficiency, labor savings, and reduced material costs. SEVERSTAL was extremely satisfied, with actual tensile strength exceeding 90% of the base material, even surpassing it, earning high recognition and praise from the customer.