Such properties include free peeling slag and good transfer of the chemical composition of the welding electrode to the weld puddle. Fluorides: Common electrode coating and flux material for both low- and high-alloy steels. The flux is rendered non-hygroscopic by heating the ingredients to a temperature in the range of 1,450* F. to about 1,800* F. [451 May 16, 1972 [54] WELDING FLUX COMPOSITION [72] Inventors: James E. Oberly, Keamy; Thomas L. Coless, Maplewood; K. Woodrow Rimer. TiO2 proportion in welding flux composition is small, but it plays an important role. The electrode wires used for submerged arc welding are given in American Welding Society specification, “Bare Mild Steel Electrodes and Fluxes for Submerged Arc Welding.” This specification provides both the wire composition and the weld deposit chemistry based on the flux used. It lowers adhesion between slag and liquid metal and improves slag detachability of agglomerated flux. 4.04.2.3 Ni-Base Welding Alloys. Even though most of the welding machine manufacturers have included a table of materials and voltage settings in the machine, it is highly important for you to pick the right kind of gas and electrode wire to be used for MIG welding stainless steel. Flux materials containing sufficiently low con-centrations of NORM are not subject to federal radiation control regulations. Our competitive products are agglomerated flux, fused flux, welding wires. ;ASSIGNOR:UNION CARBIDE CORPORATION;REEL/FRAME:004436/0460, Owner name: Adding metal powder alone produces a slag-free cored wire that has a higher productivity than a flux-cored wire. The weld was sound, crack-free and met all the mechanical property requirements. Melting point of MgO is relatively high. 2. coatings, fluxes; Selection of soldering or welding materials, conjoint with selection of non-metallic compositions, both selections being of interest with inorganic compounds as principal constituents. There are so many different types of welding electrodes! The slag removed easily from the weld and there was essentially no loss of alloying ingredients. - Quora. Using a flux core welder is suitable for all welding positions when used with the correct filler metal and flux composition. Check for proper alignment. 15-25% SiO2 Fluxes for brazing operate at significantly higher temperatures and are therefore mostly inorganic; the organic compounds tend to be of supplementary nature, e.g. Description: Welding Flux. It protects the weld pool and solid metal from atmospheric contamination and helps in removing impurities from the weld pool. Too early solidification makes weld metal can’t transit to groove smoothly, slag removal is also difficult. Submerged arc welding flux composition (Agglomerated flux) is generally made up of three basic components: slag forming agents, oxidants & alloying elements & modification compounds, binders. It could increase viscosity of slag, and suppress fluidity of slag. For basic welding flux, MgO could improve impact toughness of weld metal, and reduce diffusible hydrogen content in weld bead. Fluxes for soft soldering are typically of organic nature, though inorganic fluxes, usually based on halogenides and/or acids, are also used in non-electronics applications. The chemical composition of the electrode wire and flux core, in combination with the shielding gas, will determine the weld metal composition and mechanical properties of the weld. The effects of wire/flux combination on the chemical composition, tensile strength, and impact toughness of the weld metal were investigated and interpreted in terms of element transfer between the slag and the weld metal, i.e., Δ quantity. These assignments have been based on comparable base metal characteristics, such as: Composition However, since the composition of a cored wire may be different from that of its weld deposit the composition must be determined from a low dilution weld deposit made using a specific, named flux. ;REEL/FRAME:004610/0384, High penetration, high speed, agglomerated welding flux, High-efficient energy-saving and surfacing layer well-forming self-shielded flux-covered welding wire and manufacture method, Electrodes and flux for arc welding stainless steel, Submerged arc flux and method of making same, Magnesium removal from aluminum alloy scrap, Method of submerged arc welding high tensile strength steel having trace elements of vanadium or niobium, Tubular composite welding wire filled with potassium compounds containing flux, Arc welding process and electrode for stainless steel, Flux for brazing difficult to wet metallic materials, Scrap brass smelting auxiliary and preparation method thereof. The fused slag was free-peeling. Metal powder-filled cored wires contain a powder that consists mainly of iron and alloying elements. This is an incomplete question. It is easy to form undercuts and pits on weld bead. Carbon is the primary hardening element in steel. SiO2 is added in the form of mineral powders, silica, Ferrous alloy, water glass, etc. Flux Cored Arc Welding is an automatic or semi-automatic arc welding process using a wire that contains flux in its core. The flux may be the coating on the electrode, inside the electrode as in flux cored types, or in a granular form as used in submerged arc welding. The resultant weld pool has a sufficiently high oxygen level to produce a slightly convex or flat weld joint profile. When SiO2 content is higher than 20%, submerged arc welding flux could transfer Si to weld metal. The coating is used on electric welding rods and serves several functions. [73] Assignee: Union Carbide Corporation, New York, [22] Filed: June 15, 1970 [2]] Appl. It has excellent welding properties and is suitable for grinding, … SiO2 adding by different ways could improve comprehensive welding performance. FCAW-S and FCAW-G. And after burning, it creates shielding gases and produces welds. Nonetheless, many investigators have attempted to define the effective equilibrium by empirical analysis of experimental data. Tests prove that, when MgO content is higher than 30%, slag detachability goes bad. Below are the functions of oxidants in welding flux composition: 10-25% CaF2 QW-404.4 – The welding wire was ER80S-D2 for GTAW and ER70S-6 for GMAW ASME Section II, SFA 5.28 specifies low -alloy steel electrodes for gas shielded arc welding ASME Section II, SFA 5.18 specifies carbon steel electrodes for gas shielded arc welding Table QW-432 Paragraph Depending on their composition or alkali to silica ratio they begin to soften at approximately l,150 F. and become completely molten between l,400 F. and l,550 F. It is theorized therefore that when the flux mixture is heated to temperatures of between 1,450 F. and l,800 F., CaCO, con- The flux which includes CaO is then impervious to water absorption after cooling. 5. Interdiffusion between the adatoms and the substrates. No cover gas or flux is used, thereby making the process environmentally friendly. Flux composition of sputtering source. 4. ;ASSIGNOR:UNION CARBIDE CORPORATION, A CORP OF NY. What is the Chemical Composition of welding electrode? Water glass obviously improves arc stability, granular strength and resistance to water absorption. Add: Zhongling Village, Dayugou Town, Gongyi City, Henan Province, China. If in the manufacture of the flux the constituents are heated above about l,5l7 F., the. ' (shielded metal arc welding).. '70' tells that the the tensile strength of the resulted weld is 70,000 psi. A flux coating is a layer of a chemical which acts as a cleaning agent, a purifying agent or a flowing agent. Submerged arc welding fluxes are generally referred to as fused fluxes or bonded fluxes. No. It protects the weld pool and solid metal from atmospheric contamination … 48 weight per cent CaCO, 27 weight per cent ZrSiO 10 weight per cent Na AlF. : 46,529. Self-shielded flux-cored wires are commonly abbreviated as FCAW-S wires, with the “S” at the end notifying operators of their self-shielding capabilities. Below are the functions of oxidants in welding flux composition: 10-25% CaF2. Shell Internationale Research Maatschappij B.V. Lincoln Global, Inc., A Delaware Corporation, Jiangsu University Of Science And Technology, L-TEC COMPANY, 666 THIRD AVENUE, NEW YORK, NY 100, ASSIGNMENT OF ASSIGNORS INTEREST. Such flux system also includes zircon sand and cryolite as additional slag forming ingredients in order to produce a flux system having all the desired properties for surfacing low alloy steels with stainless steel.. In addition, SiO2 is surface active agent, which could reduce slag surface tension. Welding of nickel–chromium–iron alloys is typically performed using arc-welding processes such as gas-tungsten-arc welding (GTAW), shielded-metal-arc welding (SMAW), and gas-metal-arc welding (GMAW). L-TEC COMPANY, EBENEEZER ROAD, POST OFFICE BOX F-6, Free format text: Bare rods or wire When MgO content is higher than 30%, it makes weld bead formation bad. (2.4- or 3.2-mm) diameter electrodes. Stick welding, or shielded metal arc welding, has been around more than 100 years. However, up until now large quantities such as 30 to 60 weight percent have not been used. It plays the roles of lowering slag basicity, reducing slag melting point, improving weld bead formation. The CaO remaining in the flux is hygroscopic and will pick up water which is harmful to the weld. Al2O3 could also increase surface tension of slag. Different flux chemistry changes the characteristics of the arc, how it performs, and in what positions. They are considered soluble glasses which do not exhibit a sharp melting point. to make the flux sticky at low temperature so it can be easily applied. Weldability of reinforcing steel and compatibility of welding procedures need to be considered and closely supervised when manual arc welding of reinforcing steel is required. FLAME CUTTING; WORKING BY LASER BEAM, Rods, electrodes, materials, or media, for use in soldering, welding, or cutting, Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material, Selection of non-metallic compositions, e.g. Flux-cored arc welding is an internal shielding process and produces some spatter as well. flux compositions depending on the weld streng ths they intend to achieve; this being the criterion for developing their own unique flux compositions. B23K35/3601—Selection of non-metallic compositions, e.g. 5 4 10 14 Sodium Silicate 8 4 6 8 Potassium Silicate 4 2 MgO l0 20 FeSi 2 2 FeCr 3 1 SiO, 8. Multiple beads were deposited side by side to produce a single layer. If addition of Al2O3 is too high, it is hard for slag detachability improvement. When Al2O3 content is higher than 20%, viscosity is too high. coatings, fluxes; Selection of soldering or welding materials, conjoint with selection of non-metallic compositions, both selections being of interest, Selection of non-metallic compositions, e.g. Accordingly, it is the main object of this invention to provide a flux for welding or surfacing which permits good transfer of the chemical composition of the welding electrode .to the weld. F. At these temperatures, the CaCO, converts to CaO and gaseous C0,. °C (°F) 150 °C 150 °C However, specific welding flux compositions within the standard limits depend on the particular manufacturer and raw materials available. This discovery was used in the development of a flux system comprising 30 to 60 weight percentCaCO, for surfacing low alloy steels with stainless steel. ASSIGNMENT OF ASSIGNORS INTEREST. The flux compound, located within the continuous hollow wire electrode, protects the weld pool adequately. Slag becomes too viscous, fluidity declines. Flux Cored Electrodes – A composite tubular filler metal electrode consisting of a metal sheath and a core of various powdered materials, producing an extensive slag cover on the face of a weld bead. Specific flux compositions contain large quantities of titanium oxide, which is also known as rutile. Introduction. The composition contains calcium carbonate as its major ingredient together with a sodium or potassium silicate binder. Acute effect is irritation of the eyes, nose and throat. It is well known that the slag and metal do not reach equilibrium during fluxshielded welding, due to the short reaction times and large thermal gradients inherent in the process. Flux Trade Name and Flux Type (SAW) N/A N/A Consumable Insert, Class and Size _ _ Other information: This is a DEMO WPS from www.WPSAmerica.com POSITIONS (QW-405) Position (s) of Groove ALL Position ALL Position Welding Progression Up Up Position (s) of Fillet ALL Position ALL Position PREHEAT (QW-406) Preheat Temp. There a pretty good selection and variety of Welding rods.a 7018 rod.E7018 Welding rod is used for SMAW. Like FCAW, SMAW uses flux to protect the weld pool from damaging atmospheric gases – the only difference is that in SMAW the flux coats the … A B C D CaCO, 35 55 40 50 ZrSiO, 40 20 24 25 Na,AlF. After processing according to the above procedure, the preferred flux composition given above had the following analysis: CaO 32 wt.%; CO, 1.0 wt.%; ZrSiO, 35 wt.%; SiO, 5.5 wt.%; Na,AlF, 12 wt.%; Na,O:SiO, 7.5 wt.%; K,0:Si0, 1.5 wt.%; FeCr 3 wt.%; FeSi 2.5 wt.%. This article discusses some of the characteristics of wires and fluxes. Review on effect of flux composition on its behavior and bead geometry in submerged arc welding (SAW) Brijpal Singh1, Zahid Akthar Khan2 and Arshad Noor Siddiquee2 1Department of Mechanical Engineering, Maharaja Surajmal Institute of Technology, C-4, Janakpuri, New Delhi, 110058, India. Flux cored arc welding (FCAW) is an arc welding process where coalescence is produced by heating with an arc between a continuous filler metal electrode and the work. 1-3% TiO2 ;REEL/FRAME:004610/0384, ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:UNION CARBIDE CORPORATION, A CORP OF NY. The results of these analyses have generally been contradictory and, in most … The next article will review the specifications. Since both the wire and the flux will have an effect on the weld metal composition, and hence on the mechanical properties, the welding engineer is faced with choosing the appropriate wire/flux combination for the application. A 7018 is different from a 7024, a 6010 or 6011. Owner name: SiO2 is acid oxidant. Alloys such as Monel, brass, bronze. Welding defects like undercut, slag inclusion would occur. Mobile/Whatsapp/Wechat: +86 18530036598 The composition contains calcium carbonate as its major ingredient together with a sodium or potassium silicate binder. Flux Core Welding Advantages Sticking coefficient of adatoms. A granular submerged arc bonded welding composition consisting essentially of: 48 weight per cent CaCO3 27 weight per cent ZrSiO4 10 weight per cent Na3AlF6 6 weight per cent Sodium Silicate 1 weight per cent Potassium Silicate 4 weight per cent SiO2 2 weight per cent FeCr 2 weight per cent FeSi. For purposes'of this disclosure and the claims appended hereto the flux composition is defined in terms of starting ingredients. These fluxes do not present an environmental or health hazard. 4130 chrome-moly can be welded with the TIG or MIG process. Copyright@2015-2017 Gongyi Yulin Welding Material Co. Ltd.| All Right Reserved. ,(ZrSiO about 4 weight percent to about 20 weight percent cryolite (Na,AlF,) and at least one-silicatetaken from the class of silicates consisting of potassium and sodium silicates present in the amount of from about 4 to about 10 dry weight percent. This program prepares welders for most phases of the industry. We can distinguish between metal - cored arc welding (MCAW) and flux - cored arc welding (FCAW) wires. The flux of claim 8 wherein cadmium chloride and cuprous chloride are in the proportion of about 1 to 3. The chemical analysis of the deposit was as follows. Assigned to SECURITY PACIFIC BUSINESS CREDIT INC., A DE CORP. SECURITY PACIFIC BUSINESS CREDIT INC., A DE CORP. SECURITY INTEREST (SEE DOCUMENT FOR DETAILS). 6 weight per cent Sodium Silicate 1 weight per cent Potassium Silicate 4 weight per cent SiO, 2 weight per cent FeCr 2 weight per cent FeSi, 2. ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:UNION CARBIDE CORPORATION, A CORP OF NY. For shielded metal arc welding (SMAW), the flux covered electrode ECuNi is used with direct current electrode positive (reverse polarity). Welding 4130 Chrome-Moly. Choose proper welding current. Thus, it is good for weld pass formation. The next letter, 'L', 'M' or 'H' indicates a low (0.6% max), medium (1.4% max) or high (2.2% max) manganese content. SECURITY INTEREST;ASSIGNOR:L-TEC COMPANY A NY LIMITED PARTNERSHIP;REEL/FRAME:004445/0860, Owner name: Acute effects include irritation of the eyes, nose and throat, nausea and "Metal Fume Fever." Cl ..B23k 35/38 [58] Field of Search 148/24, 26, 23; 219/73 [56] 7 References Cited UNITED STATES PATENTS 3,328,212 6/1967 Coless ..l48/26 3,551,217 12/1970 c61ess.....' ..14s/'26 3,480,487 11/1969 Coless et a1 ..l48/26 2,814,579 11/1957 Stringhametal... ....l48/26 2,895,863 7/1959 Stringhametal... ....148/26 3,340,107 9/1967 1311116856181. Each bead was made with 30 volts in each wire with 450 amperes and a travel speed of ipm. Preheat is generally not needed for thinner sections (0.120-in), but for tubing larger than 0.120 a 300F-400F preheat is needed to obtain acceptable results. It is a flexible welding process suitable for all position welding, given the correct filler material and flux composition. EXAMPLE ll Two and one-half inch thick ASTM 304 stainless steel plates were welded using the submerged arc process. Thus, if CaO could be rendered nonhygroscopic, CaCO, would be a desirable flux ingredient especially for welding or surfacing of stainless steel alloys. As will be noted .from the above table, other ingredients such as MgO may be used in conjunction with the slag forming ingredients to produce desired flux systems according to the teaching of this invention. Mineral materials. As a basic oxidant, CaF2 could increase basicity of slag and improve low temperature impact toughness of weld metal. 3. Surface reaction of the adatoms. Fax: +86-371-64054446 For example, other metals are Nickel, Columbium, Molybdenum, Manganese, Titanium, Calcium, Vanadium, Cobalt and Aluminum. An externally supplied shielding gas is sometimes used, but often the flux itself is relied upon to generate the necessary protection from the atmosphere, producing both gaseous protection and liquid slag protecting the weld… Shielded Metal Arc Welding (SMAW) electrodes are designated by “E” followed by four (or five) digits for example: E7018, E6013 or E10018. Contact: Mr. Charlie The mixture is passed through a rotating kiln where it is heated to a temperature between 1,450" F. and 1,800? SMAW – ‘SMAW’ stands for ‘Shielded Metal Arc Welding’, but you might commonly hear it being referred to as ‘stick welding’. Alternative gases that you can use are 98% Argon and 2% Co2 or 98% argon and 2% oxygen mix. Postcode: 451271 Sodium and potassium silicates are commonly used as binders for submerged arc flux ingredients. It combines classroom time with practical experience in the most common manual and semi-automatic welding processes: OFW (gas), SMAW, GMAW, FCAW, GTAW, SAW (arc), MIG, and TIG. 16. Disadvantage is, during welding marble decomposes and produces much gases, which result in too high gas pressure in arc area, weld indentation on weld pass, fumes & smokes, air pollution. 5-15% CaO The composition of the present invention is made by sizing the raw materials, as desired. Flux: N/A Electrode-Flux (Class): N/A Composition: N/A Gas 90/10 Ar/Co2 Flow Rate 35 Cfh Cup Size 5/8 in Contact Tube to Work Distance 5/8 to 3/4 in. It is because MgO can increase surface tension of slag. Solar Welding Flux. F2 gas generated by decomposition of CaF2, which has the same effect of carbonate, reduces the partial pressure of arc atmosphere. A flux coating is a layer of a chemical which acts as a cleaning agent, a purifying agent or a flowing agent. This flux compound forms a gas as it reacts with the welding arc. L-TEC COMPANY, 666 THIRD AVENUE, NEW YORK, NY 100, Free format text: SECURITY PACIFIC BUSINESS CREDIT INC., A DE CORP. Free format text: L-TEC COMPANY, NEW YORK, Free format text: For gas metal arc welding, the wire is classified using 100% CO 2; however, argon-oxygen-carbon dioxide combinations may L-TEC COMPANY, SOUTH CAROLINA. The high welding speed and portability of this welding method means that it is widely used in construction. TiO2 lowers melting point of slag, improves slag plasticity and fluidity. A multipass welding technique was used The fused slag was easily removed after each pass. It was found, for example, that a preferred flux containing 48 weight percent CaCO,; 27 weightpercent ZrSiOr, l0, ' weight percent Na,All-,; 6 weight percent sodium silicate; 1. weight percent potassium silicate 4 weight percent Si0,; and 2 weight percent each of ferrochrome and ferrosilicon produced stainless steel weld beads on low alloy steel that were porosityfree with good contour. The resulting beads had a uniform low penetration pattern. ASTM A36 is the most commonly used mild and hot-rolled steel. FCAW provides high deposition rates, enhancing the process's productivity and quality welds with an excellent appearance. Solar Flux is mixed with alcohol (methanol/methyl alcohol preferred) and brushed on the weld joint. Assignors: UNION CARBIDE CORPORATION, A CORP OF NY. CaF2 decomposes during submerged arc welding and reduces hydrogen content of weld metal. If considerable CaCO, is present'in the flux, CO, gas remains available to be released in the heat of the arc thereby causing distortion of the weld and poor weld quality, i.e., porosity. Chemical analysis of the weld beads showed nominally wt.% chromium; 10 wt.% nickel; and 0.05 wt.% carbon which meets the chemical specification for the application. Ferrous metals which have specified impact test requirements have been assigned Group Numbers within P-Numbers. CaCO, decomposes into CaO and gaseous C0,. Water glass is used as binding agent. 20-30% MgO Shielding ... major component ranging from 10-20% of the fume composition. In this article, we summary the influences of each welding flux component (agglomerated flux) on welding performance, especially when basicity is within 1.0-2.2. 9. EXAMPLE I lows: two /32 inch diameter 3091. wires were connected in a series AC circuit. ;ASSIGNOR:UNION CARBIDE CORPORATION;REEL/FRAME:004436/0460, ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:UNION CARBIDE CORPORATION;REEL/FRAME:004436/0460, SECURITY INTEREST;ASSIGNOR:L-TEC COMPANY A NY LIMITED PARTNERSHIP;REEL/FRAME:004445/0860, L-TEC COMPANY, EBENEEZER ROAD, POST OFFICE BOX F-6, ASSIGNMENT OF ASSIGNORS INTEREST. Bend tests taken from the weld beads were free from fissures and cracks indicating a sound deposit. Email: charlie.ylflux@gmail.com. The welding electrode, which is commonly known as “welding rod,” is a piece of flux-coated metal wire that also acts as filler when used in the welding process known as the “shielded metal arc welding” or SMAW.In the SMAW process, also commonly referred to as “stick” welding, the welding rod (a.k.a. Usually, the bonded ingredients are heated from a minimum temperature of 600 F. to a maximum temperature of about 2,000 F. There has been a need in the art for a bonded submerged arc flux that is more suitable for stainless steel welding or surfacing low alloying steels with stainless steel. In this article, we summary the influences of each welding flux component (agglomerated flux) on welding performance, especially when basicity is within 1.0-2.2. On the other hand, CaO is a desirable ingredient in submerged arc fluxes for welding or surfacing metals such as stainless steel because CaO is nonreactive with constituents of stainless steel. The metals, their alloys, or their ferroalloys, such as SiMn, FeSi and FeCr, can be added as desired for deoxidizing purposes or for alloying to adjust the weld chemistry. Al2O3 is added in the form of corundum and bauxite. FCAW is mainly two types i.e. ;REEL/FRAME:004610/0384, Owner name: A bonded welding composition or flux for welding or surfacing of metals which is free-peeling, essentially non-hygroscopic. … Mode of Metal Transfer CaO in agglomerated flux could increase slag basicity and improve weld metal mechanical properties. The welding electrode was ASTM 308 stainless steel, 1/8 Dia. 18-20% K-Na water glass B23K35/3602—Carbonates, basic … Here's what you need to know about this important welding consumable. The coating is used on electric welding rods and serves several functions. Assignors: L-TEC COMPANY A NY LIMITED PARTNERSHIP. [5].Standard welding flux composition ranges exist [6]-[8]. The potassium and sodium silicates in liquid form are added to form granules. The technological performance of the optimum flux compositions with respect to the bend test was 230kN/m2. If the arc length is kept short, the weld pool can be controlled in all positions with a 3/32- or 1/8-in. Chemical Composition Physical Properties Mechanical Properties Machining Welding Heat Treatment Applications. Solar Flux is a complex chemical compound in the form of a very fine powder. The sized materials are dry blended thoroughly.

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