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QUESTIONS ABOUT FLUX

What is FLUX?

A Flux is a chemical product that is necessary to joining metals by heat by soldering, brazing, or welding. Solder flux performs three important functions:

1. It removes metal oxides and prevents re-oxidation.
2. Fluxes allow the solder to flow over the surfaces, allowing the solder to flow over the metals to be joined.
3. They improve the heat transfer from the heat source to the metals that are to be joined.

 

I am just starting up radiator manufacturing plant. What fluxes should I use?

A General Chemicals Technical sales staff can assist you in selecting the appropriate fluxes for your application. Email to sales@generalchem.com

 

I am just starting up a cast on strap battery line. What fluxes should I use?

A General Chemicals sales staff can assist you in selecting the appropriate fluxes for your Application. Email to sales@generalchem.com
I own a radiator repair shop. What flux do I use for hand torch soldering?

A HI-FLO 5133, HI-FLO 2000, and HI-FLO 2150 are commonly used for this application. Contact sales@generalchem.com for specific recommendations.
We are soldering with non zinc chloride acid (water based) flux. How long can we leave the flux residue on the assembly before cleaning?

We recommend you clean as soon as possible. Some manufacturers find the amount of residue acceptable and do not clean it. However you must run test to determine your process.

COS BATTERY PROCESS

The process used to manufacture lead acid batteries is referred to as the “Cast on Strap” or COS process. There are many different brands of machinery for the Cast on Strap manufacturing process. Some of them are TBS, Farmer, and Mac/Dynacast and others.

Manufacturing Process:
The basic Principals of COS Manufacturing are the same no matter which type of cast-on-strap equipment is used. The plates are stacked manually into the envelope and group assembling machine, then the automated process begins. The plates move quickly along a conveyor as they are assorted for final alignment. Sensors will stop the process if any plates are double-stacked or misaligned.

As they move along, the plates are individually brushed clean. Then they are enveloped to the exact size to fit their particular battery case. These enveloped plates now enter a chamber where the edges are joined ultrasonically and sealed to the plates. Enveloped (positive) and un-enveloped (negative) plates are then stacked together alternately. Then they are grouped and re-stacked to align them for the next process.

Soldering Flux Application:
The lugs on each plate are mechanically aligned for proper positioning before the casting operation. Six groups of plates are “picked and placed” in the COS (cast on Strap) jig box for casting. Each group is a cell and each cell contains 2.1 volts, which equals 12.6 volts or a “12 Volts Battery”. The lugs are automatically aligned and simultaneously brushed with NoRez®65 or NoRez00_2COS flux to prepare them for the casting Process.

The lead is fed through enclosed pipes at a temperature of 450° -550°C and poured into the mold block which is maintained at a temperature of 150°-200°C. A pump in the mold block fills the mold cavity with lead. The design of the mold allows excess lead to quickly drain off leaving the desired cast level. Then special water ring circuit cools the casting and an injection system frees it from the mold. This entire procedure is monitored and controlled electronically. The strap connections will now provide a series circuit between the lead plates. The battery is then unloaded cased, and sealed.

Lead free alternatives are not a real consideration at this time due to cost considerations. Most of the lead acid battery is encased in plastic and batteries are fully recyclable. Compliance with environmental regulations, therefore, is not difficult.

General Chemical Corp provides the CAST-ON —STRAP Battery manufacturers with Fluxes. No Rez® 65 is an aqueous based flux used for standard evaporation No Rez®-2COS is a solvent based flux it is a halide free COS flux. This flux is designed for Facilities looking to Eliminate halides in there process.

TALKING ABOUT METALWORKING LUBRICANTS

Metalworking lubricants perform several functions. They protect or improve surface finish, provide corrosion protection, reduce frictional forces, cool the tooling, prevent metal pick-up on the tooling, and they flush away the chips created in a machining operation. To perform these functions they contain complex blends of a carrier, lubricity additives, corrosion inhibitors, biocides, and antifoams.

The major components of a lubricant are the carrier, lubricity additives, and in emulsions an emulsifier. Carriers are petroleum oils, water, or solvents. Their function is to provide cooling, act as a vehicle for the other additives, and flush away chips. Water based lubricants are preferred in metal machining because water removes heat caused by friction and metal removal almost twice as fast as oil. Solvents are used in vanishing lubricants that leave no or little residue.

Lubricity Additives
1. Petroleum oil
2. Polar additives
3. Extreme pressure additives

Petroleum oils by themselves are not very good metalworking lubricants. Their lubricating films can take only light loading. They are use on single spindle automatics such as screw machines, lathes where free machining brass and steels are the main metals being machined. They are seldom used in stamping and drawing.

Polar additives are of two kinds: those derived from fatty oils such as lard oil and long carbon chain polymers. They have a positive charge at one end of the molecule and a negative charge at the other end. The negative end is attracted to the positive charged metal, and aligns itself at right angles to the metal surface. The positive ends of the molecules, both on the metal being worked and the tool (cutting or die) repel each other, preventing metal-to-metal contact. This is termed polar lubricity.

Extreme pressure additives are sulfurized or chlorinated fatty oils, fatty oils that have both sulfur and chlorine on the same molecule, and phosphorus compounds. They function by reacting with the metal surfaces of the cutting tool or die to form a sulfide, phosphide, or chloride compound. These compounds have plate like structure, similar to graphite, allowing the work piece and the tool to slide against each other. This reduces friction and in the case of metal cutting reduces the cutting force and in stamping and drawing lowering

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ENVIRONMENTAL POLICY

General Chemical Corp. is committed to:

  • Preventing Pollution
  • R&D of Environmental friendly product
  • Compliance with Laws and Regulations
  • Environmental Objectives
  • Continual Improvement of Environmental Performance
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SHELF LIFE POLICY

CHEMICALS: The date of manufacture is noted as part of the Control Number. The date of manufacture is as close as possible to the shipping date as the chemical product is certified prior to final packaging. You can ask General Chemical about Shelf Life on a particular product. Shelf life is also dependent upon care of open container of the product, storage temperature and other environmental conditions.
Note: The information presented herein is our interpretation of certain test results and field experience to date. The information is not to be taken as warranty or representation for which we assume legal responsibility, nor as permission or recommendation to practice any patented invention without a license. It is offered solely for your consideration, investigation and verification.

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