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Fluxes For Welding: BY Jabin Mathew Benjamin 13MY04 Dept. of Metallurgical Engineering
Fluxes For Welding: BY Jabin Mathew Benjamin 13MY04 Dept. of Metallurgical Engineering
BY
JABIN MATHEW BENJAMIN
13MY04
DEPT. OF METALLURGICAL ENGINEERING
12/25/2014
Oxide Formation
Sources of O2
Oxide fluxes
Atmosphere air
Slag-metal reactions
Effects
Reduces
hardenability of weld
Promotes porosity
Produces inclusions
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Inclusion Formation.
Sources of inclusions
Mechanical entrapment of nonmetallic slag
Reactions between metallic alloy elements and nonmetallic
tramp elements
Types
Oxides
Sulfides
Nitrides
Carbides
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FLUXES
4
Covers the hot weld metal and protects it from the atmosphere.
Types Of Fluxes
5
Halide-type fluxes
CaF2NaF
CaF2BaCl2NaF,
KClNaClNa3AlF6
Oxygen free
Used for Al and Ti
Halideoxide-type fluxes
CaF2CaOAl2O3
CaF2CaOSiO2
CaF2CaOMgOAl2O3.
Slightly oxidizing
High-alloy steels
Oxide-type fluxes
MnOSiO2
FeOMnOSiO2
CaOTiO2SiO2.
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Basicity Index
6
B.I =
B.I < 1
: ACIDIC FLUX
1 < B.I < 1.2 : NEUTRAL FLUX
B.I > 1.2
: BASIC FLUX
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Oxide Fluxes
7
Basic Oxides
K2O, Na2O, CaO, MgO
Donors of free
oxide ions
Cleaner weld
Lower non metallic
inclusions
High toughness of
weld
Greater tendency
to absorb moisture
Slag detachability
not be very good
Acidic Oxides
SiO2, TiO2, P2O5
Acceptors of oxide
ions
Excellent slag
behavior
Improves weld bead
morphology
High deposition rate
Moderate strength
weld
Rust proof
High welding speed
Amphoteric Oxides
Al2O3, Fe2O3, Cr2O3
Neutral oxide
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CaO
Strong desulfurizer
MnO
Increased penetration
SiO2
Lower content increases the width to depth ratio.
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Slag Formation
9
Properties required
Melt below the melting temperature of base metal
Density less than base metal to reduce slag entrapment
Must possess proper viscosity in the temperature range of
1450 to 1550 C
Easily detach from the weld deposit
Function
Solidify on the weld deposit to protect the surface from
oxidation during cooling.
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FCAW Fluxes
12
Carbon-dioxide-shielded FCAW
Titania
Lime
Self-shielded FCAW
Fluorspar-aluminum
Fluorspar-titania
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FLUXES USED:
Manganese silicate
Aluminate basic
Alumina
The flux is supplied from a hopper, which travels with the torch. No
shielding gas is needed because the molten metal is separated
from the air by the molten slag and granular flux.
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14
Bonded fluxes
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High viscosity
Confine the molten weld pool
Increases the heat input for a given area
Deeper penetration.
Flux composition
Affects arc stability
More ionized particles more stable arc
A more stable arc will produce deeper penetration
Surface tension
Increases weld penetration.
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Reference
17
(1977).
Janzen, H. E "An Investigation of the SiO-MnO-CaO/CaF2 Welding
Flux System, "Thesis, Colorado School of Mines,T-1970, (1977).
ASM handbook, Vol. 6.
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18
THANKYOU
12/25/2014