Thesis College of Engineering University of Rizal System-Morong 2024

Generally, this study aimed to develop a small-scale extrusion press for the shielded metal arc welding electrode with a flux coating of coconut shell ash. Specifically, this study developed a sustainable alternative, a shielded metal arc welding electrode with a flux coating made from coconut shell ash. To evaluate the usability and weld quality, welders from TESDA Center Tanay, Rizal conducted visual inspections, assessing factors like depth of penetration, spatter control, ease of slag removal, overall appearance of the weld bead, deposition rate, and welder appeal. Additionally, MIRDC-DOST performed destructive mechanical testing to determine the electrode's yield strength and flexural strength. Furthermore, the acceptability of the small-scale extrusion press used for electrode production was evaluated by 31 TESDA welder respondents. This evaluation focused on the press's functional suitability for consistent electrode production, performance efficiency in terms of production rate, reliability in maintaining operation without breakdowns, and safety features to protect users. The entire production process for the coconut shell ash flux electrode, including the heat treatment step crucial for optimal performance, took approximately one week. In guiding the research in attaining the intended objectives, developmental, experimental, and descriptive research methods were considered. The small-scale extrusion press for the shielded metal arc welding electrode with a flux coating of coconut shell ash was evaluated through a researcher-modified questionnaire. The SMAW electrode produced by the device was tested by the Department of Science and Technology (DOST) – Metal Industry Research and Development Center; the device and products of the study were evaluated by the experts and end-user respondents. The shielded metal arc welding electrode with a flux coating made from coconut shell ash resembled traditional E6013 electrodes in physical characteristics and received positive feedback from welders, and an “Acceptable” mean rating from the questionnaire-survey. For the developed small-scale extrusion press, it received a mean rating of “Acceptable” from the TESDA respondents, in terms of functional suitability, performance efficiency, reliability, and safety. While low amperage usage limited penetration depth, the electrode offered minimal spatter, easy slag removal, and an average weld appearance. Welders found the deposition rate good but expressed concerns about the electrode's suitability. Technical lab results from MIRDC are expected to provide a more complete performance analysis, which helped the researchers and TESDA respondents assess the study. For the developed small-scale extrusion press, it received a “Highly Acceptable” rating on reliability and safety, due to its simple but durable design that produces functional SMAW electrodes; though it received an “Acceptable” rating on functional suitability and performance efficiency due to the fact that it is manually operated and has a slow production time. The study concluded that the developed small-scale extrusion press can produce functional shielded metal arc welding electrodes with a flux coating of coconut shell ash, based on the results of the findings and test results. The researchers recommend further study to attain a more convenient and effective way to control the shielded metal arc welding electrode with a flux coating of coconut shell ash in terms of amperage and position. Another recommendation is for future researchers to design and develop a way for the small-scale extrusion press to be automatically operated to increase its production rate and quality of SMAW electrodes. Keywords: Extrusion, Flux, Electrode