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FLUXES FOR WELDING
BY
JABIN MATHEW BENJAMIN
13MY04
DEPT. OF METALLURGICAL ENGINEERING
2. NEED FOR FLUXES
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Oxide Formation
Sources of O2
Oxide fluxes
Atmosphere air
Slag-metal reactions
Effects
Reduces hardenability of weld
Promotes porosity
Produces inclusions
3. NEED FOR FLUXES
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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
4. FLUXES
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Added to the welding environment to improve arc stability
The flux, by providing easily ionized atoms, plays an important
role in welding by improving arc stability.
To provide a slag and with low density
Covers the hot weld metal and protects it from the atmosphere.
To add alloying elements
To improve weld metal properties
Refine the weld pool (deoxidation and desulfurization)
To avoid formation to oxide and sulphide inclusions
5. Types Of Fluxes
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Halide-type fluxes
CaF2–NaF
CaF2–BaCl2–NaF,
KCl–NaCl–Na3AlF6
Halide–oxide-type fluxes
CaF2–CaO–Al2O3
CaF2–CaO–SiO2
CaF2–CaO–MgO–Al2O3.
Oxide-type fluxes
MnO–SiO2
FeO–MnO–SiO2
CaO–TiO2–SiO2.
•Oxygen free
•Used for Al and Ti
•Slightly oxidizing
•High-alloy steels
•Low-carbon or low alloy steels
7. Oxide Fluxes
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Basic Oxides
K2O, Na2O, CaO, MgO
Acidic Oxides
SiO2, TiO2, P2O5
Amphoteric Oxides
Al2O3, Fe2O3, Cr2O3
•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
•Acceptors of oxide
ions
•Excellent slag
behavior
•Improves weld bead
morphology
•High deposition rate
•Moderate strength
weld
•Rust proof
•High welding speed
•Neutral oxide
8. Functions of flux components
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CaO
Strong desulfurizer
MnO
Increased penetration
SiO2
Lower content increases the width to depth ratio.
9. Slag Formation
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Slag a mixture of glass and crystalline structure
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.
10. Shielded Metal Arc Welding
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Electrode is covered with flux material which performs the functions.
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Flux-cored Arc Welding (FCAW)
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Uses a hollow wire filled with flux reagents and ferro-additions.
12. FCAW Fluxes
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Carbon-dioxide-shielded FCAW
Titania
Lime
High CO2 content as carbonates
Self-shielded FCAW
Fluorspar-aluminum
Fluorspar-titania
Low CO2 content
13. Submerged Arc Welding
FLUXES USED:
•Manganese silicate
•Aluminate basic
•Alumina
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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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Bonded fluxes
Non metallic and ferro additions with low temperature
binders
Agglomerated fluxes
Similar to bonded but used with ceramic glass binder
cured at high temperature
Fused fluxes
Homogeneous glass mixture of proper flux mixture into
water
15. Fluxes and Weld Penetration
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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.
16. Finally a welding flux must also..
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Stabilize arc and control arc resistivity
Permit use of different types of current and polarity
Promote slag detachability
Produce smooth weld contour
Reduce spatter and fume
17. Reference
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Jackson, C. E., "Fluxes and Slags in Welding," W. R. C Bulletin, 190,
(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.