Fine-Tuning Weld Metal Compositions via Flux Optimization in Submerged Arc Welding: An Overview

doi:10.11900/0412.1961.2021.00148

Acta Metall Sin

2021, Vol. 57

Issue (9): 1126-1140 DOI: 10.11900/0412.1961.2021.00148

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Fine-Tuning Weld Metal Compositions via Flux Optimization in Submerged Arc Welding: An Overview

WANG Cong(

), ZHANG Jin

School of Metallurgy, Northeastern University, Shenyang 110819, China

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WANG Cong, ZHANG Jin. Fine-Tuning Weld Metal Compositions via Flux Optimization in Submerged Arc Welding: An Overview. Acta Metall Sin, 2021, 57(9): 1126-1140.

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Abstract

Flux is an indispensable consumable for submerged arc welding. Owing to the occurrence of complex chemical reactions between flux (slag), weld pool, and arc plasma, flux plays an essential role in determining the final composition of weld metal. To ensure a sound weldment, understanding how submerged arc welded metal compositions are fine-tuned by flux optimization is necessary. Herein, recent progress regarding the control mechanisms of fluxes on submerged arc welded metal compositions is studied. Particularly, the element transfer behaviors of major elements, including oxygen, silicon, manganese, titanium, and carbon, are documented from thermodynamic perspectives. Salient element transfer features incurred by the application of high heat input welding are interpreted. Moreover, the capabilities and limitations of prevailing compositional prediction models are evaluated. Finally, fundamental challenges to be explored further are discussed.

Key words: submerged arc welding welding flux composition prediction high heat input welding

Received: 08 April 2021

ZTFLH:

TG445

Fund: National Natural Science Foundation of China(U20A20277);Fundamental Research Funds for the Central Universities(N2025025);Xingliao Talents Program(XLYC1807024);Liaoning Key Industrial Program(2019JH1/10100014);Regional Innovation Joint Fund of Liaoning Province(2020-YKLH-39);Royal Academy of Engineering(TSPC1070);Open Foundation of State Key Laboratory of Metal Material for Marine Equipment and Application(SKLMEA-K201903)

About author: WANG Cong, professor, Tel: 15702435155, E-mail: wangc@smm.neu.edu.cn

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https://www.ams.org.cn/EN/10.11900/0412.1961.2021.00148 OR https://www.ams.org.cn/EN/Y2021/V57/I9/1126

Fig.1 Schematics of the transverse section of a weld bead

Fig.2 Reaction zones contributing to weld metal compositions in submerged arc welding

Fig.3 Expected ranges of oxygen and nitrogen contents in weld metals subjected to various welding methods (SAW—submerged arc welding, GMAW-CO₂—O₂ shielded metal arc welding, GMAW-Ar—Ar shielded metal arc welding, GTAW—gas tungsten arc welding, SMAW—shielded metal arc welding, SSAW—self-shielded arc welding)

Fig.4 Quantified level of O transfer between flux and weld metal (WM) (ΔO) value as a function of SiO₂ content in CaF₂-SiO₂ fluxes^[35,61]

Fig.5 ΔO value as a function of MnO content in CaF₂-SiO₂-MnO fluxes^[31,36]

Fig.6 ΔO value as a function of CaO content in CaF₂-SiO₂-CaO fluxes^[38]

Fig.7 ΔO value as a function of oxide level in fluxes under the heat input of 60.00 kJ/cm^[35,36,39]

Fig.8 Si transfer value (ΔSi) between flux and WM as a function of CaO content in flux and activity of SiO₂ in CaF₂-SiO₂-CaO melts at 1550^oC

Fig.9 FeO level in the slag as a function of oxygen content in the weld metal^[35,36]

Fig.10 Change of FeO content between slag and flux (δ_FeO) as a function of FeO content in FeO-SiO₂(40%)-MnO fluxes

Fig.11 Reaction interfaces associated with decarburization behaviors in SAW^[37]

Fig.12 Predicted weld metal oxygen content as a function of flux basicity index (BI)^[13]

Fig.13 Actual weld metal oxygen content as a function of MnO addition level in typical manganese-silicate type fluxes^[31]

Fig.14 Predicted weld metal oxygen contents from flux basicity model (a) and gas-slag-metal equilibrium model(b) as a function of MnO addition level in fluxes

Fig.15 Predicted weld metal oxygen contents from slag-metal equilibrium modeland gas-slag-metal equilibrium model as a function of TiO₂ addition level in fluxes^[3,24]

Fig.16 Predicted weld metal silicon contents from slag-metal and gas-slag-metal equilibrium models as a function of TiO₂ addition level in fluxes^[3,24]

Fig.17 Predicted weld metal manganese contents from slag-metaland gas-slag-metal equilibrium models as a function of TiO₂ addition level in fluxes^[3,24]

Fig.18 Predicted weld metal titanium contents from slag-metaland gas-slag-metal equilibrium models as a function of TiO₂ addition level in flux^[3,24]

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