Optimizing Microstructures and Mechanical Properties of Electro-Gas Welded Metals for EH36 Shipbuilding Steel Treated by CaF2-TiO2 Fluxes

doi:10.11900/0412.1961.2025.00028

Acta Metall Sin

2025, Vol. 61

Issue (7): 998-1010 DOI: 10.11900/0412.1961.2025.00028

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Optimizing Microstructures and Mechanical Properties of Electro-Gas Welded Metals for EH36 Shipbuilding Steel Treated by CaF₂-TiO₂ Fluxes

XIE Xu¹^,², WAN Yibo¹, ZHONG Ming¹, ZOU Xiaodong³, WANG Cong¹(

)

1 School of Metallurgy, Northeastern University, Shenyang 110819, China
2 School of Materials Science and Engineering, North China University of Water Resources and Electric Power, Zhengzhou 450045, China
3 China-Ukraine Institute of Welding, Guangdong Academy of Sciences, Guangzhou 510650, China

Cite this article:

XIE Xu, WAN Yibo, ZHONG Ming, ZOU Xiaodong, WANG Cong. Optimizing Microstructures and Mechanical Properties of Electro-Gas Welded Metals for EH36 Shipbuilding Steel Treated by CaF₂-TiO₂ Fluxes. Acta Metall Sin, 2025, 61(7): 998-1010.

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Abstract

In the shipbuilding industry and coastal engineering, thick EH36 steel plates used in vertical construction generally require joining by high heat input electro-gas welding with matching flux-cored wire to enhance production efficiency and reduce construction time. However, high heat input welding can result in high peak temperatures and slow cooling rates, leading to coarse and deteriorated microstructures in the weld metal, thereby compromising the mechanical properties of the welded joint. Given the challenge of quantifying and controlling the composition, microstructure, and properties of weld metal due to complex metallurgical reactions during high heat input electro-gas welding, five CaF₂-TiO₂ fluxes were designed, prepared, and incorporated into flux-cored wires to join EH36 shipbuilding steels with a thickness of 30 mm. The effect of TiO₂ content on the composition, microstructure, inclusions, and properties of the weld metals was systematically studied. The results indicate that as the TiO₂ content in the fluxes increases, the hardness of the weld metal decreases, while impact toughness improves. During welding, the high-temperature arc causes greater decomposition of TiO₂, leading to increased O and Ti contents in the molten pool. Simultaneously, more Si and Mn are lost into the slag through the slag-metal interface. The reduction in alloying element content shifts the continuous cooling transformation curve toward the upper left, expanding the temperature range of the ferrite phase transformation from 755-578 ^oC to 780-595 ^oC. Increasing the O and Ti contents in the weld metals raises the number density of inclusions from 4289 mm^-2 to 5327 mm^-2. The synergistic effect of multiple factors promotes an increase in the volume fraction of acicular ferrite from 9.3% to 62.1%. The morphology of key microstructures in the weld metals transitions from parallel lath bainite to interwoven acicular ferrite, refining the grain size from (53 ± 14) μm to (10 ± 5) μm and increasing the volume fraction of high-angle grain boundaries from 41.8% to 59.2%, further enhancing the impact toughness of the weld metals.

Key words: shipbuilding steel high heat input welding weld metal microstructure CaF₂-TiO₂ flux

Received: 21 January 2025

ZTFLH:

TG111.5

Fund: National Natural Science Foundation of China(W2411047);National Natural Science Foundation of China(52350610266);National Natural Science Foundation of China(52474351);National Key Research and Development Program of China(2023YFB3709900);Major Project of Liaoning Province Innovation Consortium(2023JH1/11200012);Science and Technology Development Program of Henan Province(242102231030);Marine Economic Development Project of Guangdong Province(GDNRC[2024]24);Fund of Key Laboratory for Ferrous Metallurgy and Resources Utilization of Ministry of Education, Wuhan University of Science and Technology(FMRUlab25-04)

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	XIE Xu
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https://www.ams.org.cn/EN/10.11900/0412.1961.2025.00028 OR https://www.ams.org.cn/EN/Y2025/V61/I7/998

Fig.1 Binary phase diagram and viscosities of CaF₂-TiO₂^[21] (Black and red dots represent the corresponding composition points in this work)

Table 1 Formulas of employed CaF₂-TiO₂ fluxes

Table 2 Chemical compositions of EH36 shipbuilding steel and flux-cored wire

Table 3 Chemical compositions of weld metals (WMs) (M_A)

Table 4 Dilution fractions of base material (d); nominal compositions (M_N) and transitional exchange values (ΔM) of typical elements in WM

Fig.2 SEM images and corresponding EDS results (atomic fraction, %) of typical inclusions in WMs
(a) O-Ti-Al-Mn-Si (b) O-Ti-Al-Mn-Si-S (c) O-Ti-Al-Mn

Fig.3 Normalized atomic fractions of Ti, Si, and Mn of inclusions in different WMs
(a) WM1 (b) WM2 (c) WM3 (d) WM4 (e) WM5

Fig.4 Number densities of inclusions (N) with different sizes in different WMs (d_A—average size)

Fig.5 Typical SEM images of WM1 (a), WM2 (b), WM3 (c), WM4 (d), and WM5 (e); number densities of inclusions and volume fractions of acicular ferrites (AFs) in different WMs as a function of TiO₂ content (f) (Inset in Fig.5e shows the formation of AFs induced by the typical complex inclusions in the WM)

Table 5 Average grain sizes of typical microstructures in different WMs

Fig.6 Crystallographic characteristics in WM1 (a, f), WM2 (b, g), WM3 (c, h), WM4 (d, i), and WM5 (e, j) analyzed by EBSD
(a-e) inverse pole figures (f-j) grain boundary distribution maps (The blue and red lines denote the high angle grain boundaries (HAGBs) with misorientation angle > 15° and low angle grain boundaries (LAGBs) with misorientation angle 2°-15°, respectively)

Fig.7 Effects of TiO₂ content in CaF₂-TiO₂ flux on the Vickers hardness and impact energy of WMs

Fig.8 SEM images showing the impact fracture morphologies of WM1 (a), WM3 (b), and WM5 (d)

WM number	α $T i O 2$ (mole fraction)	ΔG / (J·mol^-1)
WM1	0.102	-347767
WM2	0.121	-350996
WM3	0.137	-353342
WM4	0.167	-357084
WM5	0.198	-360302

Table 6 Activities of TiO₂ in slag (α

T i O 2

) and the corresponding Gibbs free energy changes (ΔG)

Fig.9 Volume fractions of salient phases in different WMs as a function of TiO₂ content (GBF—grain boundary ferrite, PF—polygonal ferrite, LB—lath bainite, GB—granular bainite)

Fig.10 Continuous cooling transformation (CCT) diagram shift for the WMs induced by TiO₂ content (Insets show the schematics of forming paths of salient phases in the weld metals) (T_{s, Ferrite, WM1} and T_{s, Ferrite, WM5}—starting temperatures at which supercooled austenite transforms into ferrite in WM1 and WM5, respectively; T_{s, Bainite, WM1} and T_{s, Bainite, WM5}—starting temperatures at which supercooled austenite transforms into bainite in WM1 and WM5, respectively)

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