Prediction of element transfer due to flux and optimization of chemical composition and mechanical properties in high-strength low-alloy steel weld

doi:10.1177/0954405414531113

Home
/
Papers
/
Prediction of element transfer due to flux and optimization of chemical composition and mechanical properties in high-strength low-alloy steel weld

Journal Article•DOI•

Prediction of element transfer due to flux and optimization of chemical composition and mechanical properties in high-strength low-alloy steel weld

Sandeep Jindal¹, Rahul Chhibber², N.P. Mehta¹•Institutions (2)

Maharishi Markandeshwar University, Mullana¹, Indian Institute of Technology, Jodhpur²

01 May 2015-Vol. 229, Iss: 5, pp 785-801

TL;DR: The transfer of elements C, Si, Mn, P and S from slag into the weld metal or from weld metal into the slag and microhardness has been studied using formulated fluxes.

read less

Abstract: The transfer of elements C, Si, Mn, P and S from slag into the weld metal or from weld metal into the slag and microhardness has been studied using formulated fluxes. The fluxes have been formulate...

...read moreread less

Citations

PDF

Open Access

More filters

Welding Metallurgy of

[...]

Structural Steels

01 Jan 1987

991 citations

Journal Article•DOI•

Welding Processes and Technology for Stainless Steels

[...]

Arun Kumar Bhaduri

01 Jul 2002

18 citations

Dissertation•

Design of Electrode Coatings for Bimetallic Welds

[...]

Deepak Bhandari, Rajeev Mehta, Rahul Chhibber, Navneet Arora

28 Apr 2017

TL;DR: In this paper, the authors present a table of contents and a list of tables and lists of figures, including the following categories: Table 1 Table 2 Table 3 Table 4 Table 5 Table 6

...read moreread less

Abstract: ii TABLE OF CONTENTS iii-vii LIST OF TABLES viii-x LIST OF FIGURES xi-xv CHAPTER

...read moreread less

4 citations

Cites background from "Prediction of element transfer due ..."

..., 2013, 2014a, 2014b, 2015 [68-71] tried to explore mixture design methodology for flux design in submerged arc welding process....
[...]

Journal Article•DOI•

On the Si Content Prediction for Submerged Arc Welded Metal via Calphad Technique: A Brief Discussion

[...]

Jin Zhang, L. Peng, Lizhong. Zhou, Yegao Chen

01 Oct 2022-Journal of materials research and technology

TL;DR: In this article , a gas-slag-metal equilibrium model was proposed to predict the transfer direction of Si between flux and weld metal, as well as Si content in submerged arc welded metal even when no SiO 2 is contained in the initial flux.

...read moreread less

Abstract: The slag-metal and gas-slag-metal equilibrium models have been employed via the Calphad technique to predict Si content in submerged arc welded metal. The investigated fluxes possess a wide range of basicity indices at full coverage with acidic, neutral, and basic fluxes. It is revealed that the gas-slag-metal equilibrium model offers better prediction accuracy for Si content than the slag-metal equilibrium model since the flux O potential is underestimated by the slag-metal equilibrium model. Especially, the gas-slag-metal equilibrium model is capable of predicting the transfer direction of Si between flux and weld metal, as well as Si content in submerged arc welded metal even when no SiO 2 is contained in the initial flux. Additionally, the kinetic factors that influence the transfer behavior of Si have been evaluated to interpret the deviation between measured Si content and the value predicted from the equilibrium model. At last, we have proposed the limitations of the equilibrium models, as well as the models to be further developed with respect to improving the prediction accuracy.

...read moreread less

4 citations

Journal Article•DOI•

Waste to wealth: Recycling of steel slag as flux for the submerged arc welding process and its effect on mechanical and metallurgical properties of welds

[...]

S S Saini, Kulwant Singh

30 Apr 2022-Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science

TL;DR: In this article , a novel technology has been developed to recycle steel slag as a flux for the submerged arc welding process, and the chemical, mechanical, and metallurgical properties of welds produced using recycled slag have been evaluated and compared with that of fresh flux available in the market.

...read moreread less

Abstract: A novel technology has been developed to recycle steel slag as a flux for the submerged arc welding process. The chemical, mechanical, and metallurgical properties of welds produced using recycled slag have been evaluated and compared with that of fresh flux available in the market. The tensile strengths of weld metal prepared with recycled slag and fresh flux are 462.25 MPa and 471.49 MPa, which are comparable. The impact strength of welds produced using recycled slag is 83.66 J which is acceptable in accordance with AWS SFA 5.17 specifications. The welds produced were subjected to non-destructive tests such as radiography and also dye-penetration test apart from visual inspection to ascertain the soundness of welds produced. Metallurgical investigations were carried out, and a favorable microstructure containing acicular ferrite was obtained in welds deposited using recycled slag. Similar trends of microhardness survey have been observed in both the welds produced.

...read moreread less

3 citations

References

PDF

Open Access

More filters

Journal Article•

Prediction of element transfer in submerged arc welding

[...]

P. Kanjilal, Tapan Kumar Pal, Sujit Kumar Majumdar

01 Jan 2007-Welding Journal

TL;DR: In this paper, the transfer of elements across the molten weld pool has been predicted by developing quadratic models in terms of flux ingredients with the application of statistical experiments for mixture design, and the results show that some of the individual flux ingredients and their binary mixtures have a predominant effect on weld metal transfer of oxygen, manganese, silicon, and carbon contents.

...read moreread less

Abstract: The transfer of elements across the molten weld pool has been predicted by developing quadratic models in terms of flux ingredients with the application of statistical experiments for mixture design. Bead-on-plate weld deposits were made at fixed welding parameters using submerged are welding fluxes prepared as per extreme vertices algorithm of mixture experiments in a CaO-MgO-Caf 2 -Al 2 O; flux system. The results show that some of the individual flux ingredients and their binary mixtures have a predominant effect on weld metal transfer of oxygen, manganese, silicon, and carbon contents. The analysis of experimental data also indicates that transfer of oxygen is affected by several properties of flux ingredients such as oxygen potential, thermodynamic stahility, and viscosity. In the element transfer of silicon, both thermochemical and electrochemical reaction mechanisms operate simultaneously. Transfer of manganese is principally related to the weld metal oxygen contents as well as electrochemical reaction in the molten weld pool. The transfer of carbon was generally governed by the oxidation reaction. Iso-response contour plots were also developed to quantify the transfer of elements against different flux compositions.

...read moreread less

32 citations

"Prediction of element transfer due ..." refers background or result in this paper

...Kanjilal et al.13 studied the change in element transfer (D) for the elements O2, Mn, Si, S and C in terms of flux ingredients....
[...]
...Some researchers tried to find absolute element content of the weld metal(10,11) due to slag–metal reactions, whereas others investigated the change in element transfer due to flux.(4,12,13) Pandey et al....
[...]
...Kanjilal et al.9 in their work tried to develop mathematical model to find AF in terms of flux constituents for SAW of C–Mn steel....
[...]
...CaO combines with sulfur of weld metal forming CaS and releasing O2 as per reaction mentioned in equation (17), thereby lowering sulfur content from weld metal contrary to previous results by Kanjilal et al.(13) and in agreement with the results by Chai and Eager(10)...
[...]
...CaO combines with sulfur of weld metal forming CaS and releasing O2 as per reaction mentioned in equation (17), thereby lowering sulfur content from weld metal contrary to previous results by Kanjilal et al.13 and in agreement with the results by Chai and Eager10 CaO+S!...
[...]

Journal Article•DOI•

Mixture experiments and their applications in welding flux design

[...]

Ademola Adeyeye, Festus A. Oyawale¹•Institutions (1)

University of Ibadan¹

01 Dec 2008-Journal of The Brazilian Society of Mechanical Sciences and Engineering

TL;DR: In this paper, a statistical modelling tool known as mixture experiment has been proposed for welding flux development, which has the potential to revolutionize welding flux technology. But, the limitation of the traditional approach includes: (1) long lead-time (2) expensive experiments in terms of materials and energy consumption and labour requirements (3) the flux developed can not be guaranteed to be optimal and (4) inability to identify and quantify direct and interaction effects of flux ingredients.

...read moreread less

Abstract: The traditional welding flux development has been by cost, material, time and labour intensive experiments. The extensive and expensive trial and error experimentation is needed because it is often difficult to know a priori how the flux ingredients interact to determine the operational characteristics of the flux and the final performance of the welded structure. The limitation of the traditional approach includes: (1) long lead-time (2) expensive experiments in terms of materials and energy consumption and labour requirements (3) the flux developed can not be guaranteed to be optimal and (4) inability to identify and quantify direct and interaction effects of flux ingredients. These constraints are due to the paucity of statistical modelling tools in welding flux technology. Since prediction models are derived from designed experiments, flux researchers need other methods by which flux experiments may be designed. This paper discusses a statistical modelling tool known as mixture experiment which has the potential to revolutionize welding flux development technology. Mixture design is discussed but not fully developed. The procedure of mixture experiment, analytical model forms and the sequence of model fitting are discussed. Areas of welding flux research where the various mixture designs may be useful are suggested.

...read moreread less

27 citations

Journal Article•DOI•

Effect of welding parameters on bead profile, microhardness and H2 content in submerged arc welding of high-strength low-alloy steel

[...]

Sandeep Jindal¹, Rahul Chhibber², N.P. Mehta¹•Institutions (2)

Maharishi Markandeshwar University, Mullana¹, Indian Institute of Technology, Jodhpur²

01 Jan 2014

TL;DR: In this article, an attempt has been made to optimize the weld bead parameters: weld bead form factor, dilution, microhardness and diffusible hydrogen content for welding of structural pipe steel (API 5L X65 grade).

...read moreread less

Abstract: In oil and gas industries, submerged arc welding is the only primarily used process to weld high thickness, large distance structural oil pipes. Welding process parameters play a significant role in determining the quality of a weld joint in submerged arc welding. In the present work, an attempt has been made to optimize the weld bead parameters: weld bead form factor, dilution, microhardness and diffusible hydrogen content for welding of structural pipe steel (API 5L X65 grade) by desirability function approach used by Derringer and Harrington. For design of experiments, response surface methodology had been used. Mathematical models for output responses had been developed in terms of welding parameters and checked for adequacy using t-test and analysis of variance (F-test). It was found that welding current was the most significant parameter controlling all the responses, and arc voltage had increasing effect on all the responses except microhardness.

...read moreread less

27 citations

"Prediction of element transfer due ..." refers background in this paper

...The optimum welding parameters were selected on the basis of trial runs and performing optimization experiments using response surface methodology (RSM) technique by varying the following parameters: welding current range of 349–651 A, arc voltage range of 24–32 V and weld speed range of 17–33 m/h keeping nozzle-to-tip distance constant at 25 mm with formulated flux number 11 (BI = 1.1) in separate work by Jindal et al.24 Compositions of the flux have significant effect on chemical and mechanical properties of the welds, but the effect of flux constituents on weld bead geometry has not been reported in the earlier literature....
[...]
...1) in separate work by Jindal et al.(24) Compositions of the flux have significant effect on chemical and mechanical properties of the welds, but the effect of flux constituents on weld bead geometry has not been reported in the earlier literature....
[...]
...Design of experiment (DOE) technique mentioned here was also used previously by Jindal et al.19 with same limits of flux constituents and same design table17 to determine mechanical properties and H2 content....
[...]
...Mechanical properties, ultimate tensile strength and impact strength values have been used from the previous work done by Jindal et al.19 given in Appendix 2....
[...]

Journal Article•

Control of diffusible weld metal hydrogen through flux chemistry modification : The influence of fluoride and calcite flux additions on the hydrogen content of shielded metal arc welds was examined

[...]

J. du Plessis, M. Du Toit, Petrus Christiaan Pistorius

01 Jan 2007-Welding Journal

TL;DR: In this article, the feasibility of using flux modification to reduce the as-deposited hydrogen content of basic-type shielded metal arc welds was examined, and the effect of flux additions on the weld mechanical properties and the electrode operating characteristics was not evaluated during the course of this investigation.

...read moreread less

Abstract: This project examined the feasibility of using flux modification to reduce the as-deposited hydrogen content of basic-type shielded metal arc welds. Flux formulations containing additions of fluoride-containing compounds (CaF 2 , NaF, K 2 AlF 6 , and K 2 TiF 6 ) and calcite displayed lower hydrogen levels, with the diffusible weld metal hydrogen content reaching a minimum with increasing additions. Higher levels caused an increase in the weld hydrogen content. Thermodynamic slag modeling attributes the existence of these minima to a decrease in slag water capacity with an increase in slag fluoride content (at constant basicity), brought about by higher concentrations of fluoride-containing compounds in the flux formulation. The effect of flux additions on the weld mechanical properties and the electrode operating characteristics was not evaluated during the course of this investigation.

...read moreread less

22 citations

"Prediction of element transfer due ..." refers background in this paper

...Du Plessis et al.(15) suggested that the diffusible hydrogen content of weld metal can be greatly reduced by flux chemistry modifications, that is, by increasing the BI of flux and increasing the fluoride-containing compounds (CaF2, NaF, K2TiF6 or K2AlF6) in SAW electrodes....
[...]
...Du Plessis et al.15 suggested that the diffusible hydrogen content of weld metal can be greatly reduced by flux chemistry modifications, that is, by increasing the BI of flux and increasing the fluoride-containing compounds (CaF2, NaF, K2TiF6 or K2AlF6) in SAW electrodes....
[...]

Journal Article•DOI•

Effect of Electrode Coatings on Diffusible Hydrogen Content, Hardness and Microstructures of the Ferritic Heat Affected Zones in Bimetallic Welds

[...]

Deepak Bhandari, Rahul Chhibber¹, Navneet Arora²•Institutions (2)

Thapar University¹, Indian Institute of Technology Roorkee²

01 Nov 2011-Advanced Materials Research

TL;DR: In this paper, the authors highlight the general issues and challenges for the systematic and scientific development of welding electrode coatings for bimetallic welds, and propose a method to solve them.

...read moreread less

Abstract: Bimetallic welds (BMWs) have been a necessity within the steam generators of nuclear power plants, where the heavy section low alloy steel components are usually connected to stainless steel primary piping systems. These welds represent zones with metallurgical discontinuities, which tend to localize the strains and cause failures. The other critical issues which must be taken care of while welding of bimetallic joints include solidification cracking, thermal fatigue and residual stresses in welds. The occurrence and severity of all these problems associated with bimetallic welds depend upon the type of welding process used along with the other variables like welding consumables, heat input etc. In shielded metal arc welding (SMAW), welding electrode consumables/coatings play an important role in deciding the weld metal quality. The development of welding electrode coatings is quite difficult due to very rapid complex reactions taking place during welding and the involvement of many controlled process variables. The present paper is an effort to highlight the general issues and challenges for the systematic and scientific development of welding electrode coatings for bimetallic welds. The experimental procedure contains three sets of coated electrodes having varying ferro-alloys, silica and carbon content. In the first set of electrodes, non-ferrous elements are also introduced into the weld metal through flux addition. Further, the welded joints are subjected to various tests and then evaluated to ascertain their mechanical as well as metallurgical behaviour.

...read moreread less

18 citations

"Prediction of element transfer due ..." refers background in this paper

...The primary requirement while deciding the percentage composition of various flux ingredients is that their melting temperature should be lower than that of base metals as the flux should melt first before the base metals to be melted and should remain in the molten state even after the solidification of weld so as to avoid the atmospheric contamination.(21) Slag detachment, weld bead continuity and arc stability were observed during the trial experiments....
[...]