AU2006225236B2 - Sintered flux for submerged arc welding - Google Patents
Sintered flux for submerged arc welding Download PDFInfo
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- AU2006225236B2 AU2006225236B2 AU2006225236A AU2006225236A AU2006225236B2 AU 2006225236 B2 AU2006225236 B2 AU 2006225236B2 AU 2006225236 A AU2006225236 A AU 2006225236A AU 2006225236 A AU2006225236 A AU 2006225236A AU 2006225236 B2 AU2006225236 B2 AU 2006225236B2
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- Prior art keywords
- welding
- flux
- slag
- arc
- submerged arc
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- 238000003466 welding Methods 0.000 title claims description 98
- 230000004907 flux Effects 0.000 title claims description 73
- 239000002245 particle Substances 0.000 claims description 39
- 239000000203 mixture Substances 0.000 claims description 27
- 229910004261 CaF 2 Inorganic materials 0.000 claims description 12
- 229910010413 TiO 2 Inorganic materials 0.000 claims description 10
- 229910004298 SiO 2 Inorganic materials 0.000 claims description 7
- 239000011324 bead Substances 0.000 description 53
- 239000002893 slag Substances 0.000 description 48
- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 34
- AMWRITDGCCNYAT-UHFFFAOYSA-L hydroxy(oxo)manganese;manganese Chemical compound [Mn].O[Mn]=O.O[Mn]=O AMWRITDGCCNYAT-UHFFFAOYSA-L 0.000 description 34
- 239000000395 magnesium oxide Substances 0.000 description 17
- 239000000126 substance Substances 0.000 description 16
- 238000002844 melting Methods 0.000 description 15
- 229910052751 metal Inorganic materials 0.000 description 15
- 239000002184 metal Substances 0.000 description 15
- 230000000052 comparative effect Effects 0.000 description 14
- 230000008018 melting Effects 0.000 description 10
- 229910000831 Steel Inorganic materials 0.000 description 7
- 239000010959 steel Substances 0.000 description 7
- 238000009826 distribution Methods 0.000 description 6
- 239000010953 base metal Substances 0.000 description 5
- 239000007789 gas Substances 0.000 description 5
- 230000002542 deteriorative effect Effects 0.000 description 4
- 230000000694 effects Effects 0.000 description 4
- 230000001788 irregular Effects 0.000 description 4
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicon dioxide Inorganic materials O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 4
- 239000011734 sodium Substances 0.000 description 4
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 description 4
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 3
- 229910045601 alloy Inorganic materials 0.000 description 3
- 239000000956 alloy Substances 0.000 description 3
- 230000003247 decreasing effect Effects 0.000 description 3
- 230000007547 defect Effects 0.000 description 3
- 239000001257 hydrogen Substances 0.000 description 3
- 229910052739 hydrogen Inorganic materials 0.000 description 3
- 235000019353 potassium silicate Nutrition 0.000 description 3
- 238000001179 sorption measurement Methods 0.000 description 3
- 229910004762 CaSiO Inorganic materials 0.000 description 2
- 229910001209 Low-carbon steel Inorganic materials 0.000 description 2
- 230000002378 acidificating effect Effects 0.000 description 2
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 2
- 239000010459 dolomite Substances 0.000 description 2
- 229910000514 dolomite Inorganic materials 0.000 description 2
- 238000011156 evaluation Methods 0.000 description 2
- 239000011572 manganese Substances 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 238000000034 method Methods 0.000 description 2
- 238000002156 mixing Methods 0.000 description 2
- 239000001301 oxygen Substances 0.000 description 2
- 229910052760 oxygen Inorganic materials 0.000 description 2
- 239000011148 porous material Substances 0.000 description 2
- 239000002994 raw material Substances 0.000 description 2
- 239000010456 wollastonite Substances 0.000 description 2
- 229910052882 wollastonite Inorganic materials 0.000 description 2
- 229910000851 Alloy steel Inorganic materials 0.000 description 1
- 101100290380 Caenorhabditis elegans cel-1 gene Proteins 0.000 description 1
- 101000795655 Canis lupus familiaris Thymic stromal cotransporter homolog Proteins 0.000 description 1
- 101100420769 Drosophila melanogaster scaf gene Proteins 0.000 description 1
- 229910002551 Fe-Mn Inorganic materials 0.000 description 1
- 229910017082 Fe-Si Inorganic materials 0.000 description 1
- 229910000616 Ferromanganese Inorganic materials 0.000 description 1
- 229910017133 Fe—Si Inorganic materials 0.000 description 1
- YCKRFDGAMUMZLT-UHFFFAOYSA-N Fluorine atom Chemical compound [F] YCKRFDGAMUMZLT-UHFFFAOYSA-N 0.000 description 1
- 239000006004 Quartz sand Substances 0.000 description 1
- 239000004115 Sodium Silicate Substances 0.000 description 1
- 238000005275 alloying Methods 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- 229910052661 anorthite Inorganic materials 0.000 description 1
- 238000000889 atomisation Methods 0.000 description 1
- 229910001570 bauxite Inorganic materials 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- WUKWITHWXAAZEY-UHFFFAOYSA-L calcium difluoride Chemical compound [F-].[F-].[Ca+2] WUKWITHWXAAZEY-UHFFFAOYSA-L 0.000 description 1
- 229910001634 calcium fluoride Inorganic materials 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 229910052804 chromium Inorganic materials 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 229910001610 cryolite Inorganic materials 0.000 description 1
- 230000006866 deterioration Effects 0.000 description 1
- GWWPLLOVYSCJIO-UHFFFAOYSA-N dialuminum;calcium;disilicate Chemical compound [Al+3].[Al+3].[Ca+2].[O-][Si]([O-])([O-])[O-].[O-][Si]([O-])([O-])[O-] GWWPLLOVYSCJIO-UHFFFAOYSA-N 0.000 description 1
- 238000009792 diffusion process Methods 0.000 description 1
- NJLLQSBAHIKGKF-UHFFFAOYSA-N dipotassium dioxido(oxo)titanium Chemical compound [K+].[K+].[O-][Ti]([O-])=O NJLLQSBAHIKGKF-UHFFFAOYSA-N 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 229910052731 fluorine Inorganic materials 0.000 description 1
- 239000011737 fluorine Substances 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- DALUDRGQOYMVLD-UHFFFAOYSA-N iron manganese Chemical compound [Mn].[Fe] DALUDRGQOYMVLD-UHFFFAOYSA-N 0.000 description 1
- YDZQQRWRVYGNER-UHFFFAOYSA-N iron;titanium;trihydrate Chemical compound O.O.O.[Ti].[Fe] YDZQQRWRVYGNER-UHFFFAOYSA-N 0.000 description 1
- 239000001095 magnesium carbonate Substances 0.000 description 1
- 235000014380 magnesium carbonate Nutrition 0.000 description 1
- ZLNQQNXFFQJAID-UHFFFAOYSA-L magnesium carbonate Chemical compound [Mg+2].[O-]C([O-])=O ZLNQQNXFFQJAID-UHFFFAOYSA-L 0.000 description 1
- 229910000021 magnesium carbonate Inorganic materials 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 238000010309 melting process Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229910052750 molybdenum Inorganic materials 0.000 description 1
- 230000007935 neutral effect Effects 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 239000010453 quartz Substances 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 238000005245 sintering Methods 0.000 description 1
- 229910052911 sodium silicate Inorganic materials 0.000 description 1
- 238000007711 solidification Methods 0.000 description 1
- 230000008023 solidification Effects 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N titanium dioxide Inorganic materials O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 1
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
- 229910052720 vanadium Inorganic materials 0.000 description 1
- 210000002268 wool Anatomy 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
- B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
- B23K35/36—Selection of non-metallic compositions, e.g. coatings, fluxes; Selection of soldering or welding materials, conjoint with selection of non-metallic compositions, both selections being of interest
- B23K35/362—Selection of compositions of fluxes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
- B23K35/02—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape
- B23K35/0255—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape for use in welding
- B23K35/0261—Rods, electrodes, wires
- B23K35/0266—Rods, electrodes, wires flux-cored
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
- B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
- B23K35/24—Selection of soldering or welding materials proper
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
- B23K35/40—Making wire or rods for soldering or welding
- B23K35/406—Filled tubular wire or rods
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/18—Submerged-arc welding
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Nonmetallic Welding Materials (AREA)
Description
AUSTRALIA
PATENTS ACT 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT (Original) APPLICATION NO:
LODGED:
COMPLETE SPECIFICATION LODGED:
ACCEPTED:
PUBLISHED:
RELATED ART: NAME OF APPLICANT: ACTUAL INVENTOR: ADDRESS FOR SERVICE: INVENTION TITLE: Kiswel Ltd Tae Hoon Noh LORD AND COMPANY, Patent and Trade Mark Attorneys, of 4 Douro Place, West Perth, Western Australia, 6005, AUSTRALIA.
"SINTERED FLUX FOR SUBMERGED ARC
WELDING"
DETAILS OF ASSOCIATED APPLICATION NO'S: Korean Patent Application Number 10-2005-0109937 filed on 17 November 2005 The following Statement is a full description of this invention including the best method of performing it known to me/us:
NO
N SINTERED FLUX FOR SUBMERGED ARC WELDING
O
BACKGROUND OF THE INVENTION 1. Field of the Invention F' The present invention relates to sintered flux for submerged arc welding, C and more particularly, to sintered flux for submerged arc welding of mild steel
(N
and high tensile steel of 50kgf/mm 2 used in steel frames, bridges, pipes, ships, marine structures, and so on, the sintered flux is capable of obtaining good arc stability, pockmark resistance, slag detachability, pit resistance, and bead shape when used in high-speed welding.
2. Description of the Related Art Submerged arc welding is a welding method in which powder flux is distributed to a certain thickness on a part to be welded, an electrode wire is inserted into the flux, and an arc is generated between an end of the wire and a base metal. Heat from the generated arc melts the wire, the base metal, and the flux. The melted flux forms slag, and the melted metal forms a welding bead. In submerged arc welding, since the welding arc is generated in the flux, it is not exposed to the exterior.
In submerged arc welding, since the flux is not in a melted state at the moment welding starts, current does not flow. Therefore, to facilitate generation of arc, steel wool is inserted between the base metal and the wire, or a high frequency is used. When the arc is generated, fused slag and gas are generated by arc heat, and the arc is continuously maintained.
IND
Flux for submerged arc welding may be classified as fused flux or c sintered flux depending on the manufacturing method. Fused flux is 0 manufactured by mixing raw materials, melting and cooling them in an electric furnace, and crushing them into a predetermined particle size, thereby creating crushed glass particle shapes. Fused flux has advantages of uniform chemical N composition, relatively easy removal of slag, low moisture adsorption facilitating
IND
Sstorage and treatment, and consistent particle size and composition upon reuse.
However, since fused flux should be formed through a high-temperature melting process, it is impossible to add a deoxidizer or an alloy element. That is, since the necessary alloy element should be supplied from a wire, it is very important to appropriately select the wire in the case of using fused flux. The particle size of the fused flux affects fusibility of the flux, a gas discharge state, a bead shape, and so on. The finer the particles, the higher the current applied to the particles.
When high current is applied to large flux particles, it is likely to deteriorate arc protection, make beads rough, and generate defects such as pores and undercuts.
Sintered flux is manufactured by crushing raw ore and alloy elements to an appropriate size and mixing them, adding a binder such as sodium silicate to bind them to a certain size, and drying and sintering them within a temperature range in which the raw materials are not dissolved. Since there is little loss of a deoxidizer such as Fe-Si, Fe-Mn, and so on, or an alloying agent such as Ni, Cr, Mo, V, and so on from the sintered flux, it is relatively easy to deoxidize the
C)
Smelted metal, adjust the chemical composition of the deposited metal, and o adjust the microstructure of the deposited metal.
Therefore, sintered flux is mainly used in high-tensile steel and low alloy steel requiring strong deoxidation or adjustment of chemical composition.
FOn the other hand, sintered flux has disadvantages of relatively easy adsorption, C variation in chemical components of the deposited metal in accordance with the
(N
Cwelding conditions, variation in the chemical composition of each layer in multilayer welding, difficulty in reuse due to atomization upon first use. Therefore, sintered flux should be carefully selected, treated, stored, and used.
Recently, engineers seek to increase welding speed and improve productivity in the construction of steel frames, bridges, pipes, ships, marine structures, and so on, using submerged arc welding. However, when welding at high speed with conventional sintered flux for submerged arc welding, it is difficult to obtain arc stability, pockmark resistance, slag detachability, pit resistance, and bead shape, thus lowering welding workability and productivity.
SUMMARY OF THE INVENTION The present invention solves the above problems associated with conventional sintered flux for submerged arc welding by providing sintered flux for submerged arc welding appropriate for mild steel and high tensile steel of 2 and is capable of obtaining good arc stability, pockmark resistance, slag detachability, pit resistance, and bead shape when used in high-speed welding.
00
O
O
In order to accomplish the above objects, sintered flux for submerged arc welding in accordance with an exemplary embodiment of the present invention includes 12.0- IN 24.0wt% SiO 2 24.0-38.0wt%, A1 2 0 3 6.0-13.0wt% TiO 2 2.0-9.0wt% CaO, 7.0-14.0wt% CaF 2 12.0-23.0wt% MnO, 2.0-17.0wt% MgO, 1.0-5.0wt% Na20, K 2 0, Li20 or a 5 mixture thereof, and 0.5-1.5wt% a mixture ofZrO 2 BaO, and FeO.
('4 Ci Preferably, the sintered flux for submerged arc welding in accordance with the I present invention is characterized in that basicity expressed by Formula 1 is within a range of 2.0-6.5.
[Formula 1] 2(Ca F 2 +MnO) 2.05 CaO+MgO More preferably, the sintered flux for submerged arc welding in accordance with the present invention includes 5.0wt% or less particles larger than 1.00mm, 90.0wt% or more particles of 0.20-1.00mm, and 5.0wt% or less particles smaller than 0.20mm.
DETAILED DESCRIPTION OF THE INVENTION Hereinafter, each element of the above composition will be described in detail.
Si02: 12.0 24.0wt% Si0 2 is an acidic component and functions to adjust basicity, viscosity, and melting point of fused slag to make a uniform bead shape.
IND O SiO 2 may be added as oxide or composite oxide from Quartz (Si0 2 O Quartz sand (SiO 2 Wollastonite (CaSiO 3 and so on.
When 12.0wt% or less SiO 2 is contained in the flux, it is likely to generate meandering beads or undercuts due to insufficient viscosity, irregular bead Swidth, and convex beads due to reduction of diffusion. When 24.0wt% or more N( SiO 2 is contained in the flux, basicity of the fused slag is lowered and oxygen in
(N
0 the deposited metal increases, thus deteriorating toughness. In addition, viscosity increases excessively resulting in irregular beads.
A1 2 0 3 24.0 38.0wt% Al 2 0 3 is a neutral component required for forming slag and adjusting basicity to improve welding workability. A1 2 0 3 functions to adjust viscosity and melting point of slag, and improve arc concentration and stability during high current welding, thereby improving welding workability.
When 24.0wt% or less A1 2 0 3 is contained in the flux, the viscosity and melting point are lowered to make the bead width and grain irregular and generate defects such as undercuts. When 38.0wt% or more A1 2 0 3 is contained in the flux, solidification temperature increases, causing bead deterioration, and viscosity also increases to form convex beads or generate slag inclusion.
A1 2 0 3 may be derived from sources such as Bauxite (A1 2 0 3 .2H 2 0), Aluminum oxide (A1 2 0 3 and so on.
TiO 2 6.0 13.0wt%
NO
STiO 2 is an acidic component and a slag generator which functions to o transfer Ti into welded metal during welding to improve toughness and slag detachability of the welded metal.
When 6.0wt% or less TiO 2 is contained in the flux, slag detachability is \0 Slikely to decrease, toughness of the welded metal is reduced, and undercuts CN may be formed. In addition, when 13.0wt% or more TiO 2 is contained in the (Ni 0flux, the arc is unstable, causing beads with rough grains. Further, the welded metal contains an excessive amount of Ti, which increases the probability of low-temperature cracks.
TiO 2 may be derived from sources such as Rutile (TiO 2 Ilmenite (FeTiO 3 and so on.
CaO: 2.0 CaO is a basic component useful in adjusting basicity and viscosity, and reducing oxygen in the welded metal, thereby effectively increasing toughness of the welded metal.
When 2.0wt% or less CaO is contained in the flux, there is little effect.
When 9.0wt% or more CaO is contained in the flux, bead shape and welding workability are deteriorated to generate pockmarks, and viscosity increases resulting in irregular beads.
CaO may be derived from sources such as Wollastonite (CaSiO 3 Dolomite (MgCO 3 *CaCO 3 Anorthite (CaO*AI 2 0 3 *2SiO 2 and so on.
CaF 2 7.0 14.0wt%
ID
SCaF 2 is a basic component useful in improving fluidity of slag, and O generating fluorine gas to reduce vapor partial pressure, thereby effectively decreasing an amount of hydrogen in the deposited metal.
When 7.0wt% or less CaF 2 is contained in the flux, there is little effect for shielding the welded metal. When 14.0wt% or more CaF 2 is contained in the CN flux, the arc is unstable and bead shape is deteriorated, gas is generated to 0 produce a rank smell, and pockmarks and undercuts are generated.
CaF 2 may be derived from sources such as Fluospar (CaF 2 and so on.
MnO: 12.0 23.0wt% MnO is a basic component useful in improving bead shape and adjusting a melting point and viscosity of slag during high-speed welding.
When 12.0wt% or less MnO is contained in the flux, there is little effect.
When 23.0wt% or more MnO is contained in the flux, CO excessively reacts with a melted part to remarkably deteriorate bead shape or slag detachability.
MnO may be derived from sources such as Ferro-Manganese, Manganese oxide (MnO), and so on.
MgO: 2.0 17.0wt% MgO is a basic component useful in increasing basicity of the fused slag, and moves hydrogen in the metal into the slag, thereby reducing hydrogen to improve toughness.
When 2.0wt% or less MgO is contained in the flux, its effect is insufficient such that the slag is attached to the surface of the welding beads to deteriorate
NO
detachability. When 17.0wt% or more MgO is contained in the flux, the arc is Sunstable to form convex beads, and the melting point of the slag excessively increases, thereby deteriorating detachability.
MgO may be derived from sources such as Magnesite (MgCO 3 \0 Magnesia clinker (MgO), Dolomite (MgCO 3 -CaCO 3 and so on.
(N
0Na20, K 2 0, Li 2 0, or a mixture thereof: 1.0 Na 2 0, K 2 0, and Li20 are important components for obtaining arc stability, specifically, maintaining arc stability during high-speed welding.
When 1.0wt% or less Na20, K20, Li 2 0, or a mixture thereof is contained in the flux, arc stability is significantly decreased, weld penetration is shortened, and slag inclusion is generated. When 5.0wt% or more Na20, Li 2 0, or a mixture thereof is contained in the flux, convex beads are formed to deteriorate welding workability, and the arc is considerably unstable resulting in reduced moisture adsorption resistance.
Na 2 0, K20, and Li 2 0 may be derived from sources such as water glass, Cryolite (Na 3
AIF
6 Potassium titanate (K 2 TiO 3 Li-Si, and so on, used to manufacture sintered flux for submerged arc welding.
Meanwhile, in addition to flux having the above composition, basicity expressed by Formula 1 is preferably within the range of 2.0-6.5.
[Formula 1] 2(Ca F 2 +MnO) CaO+MgO
IND
\O
SIn Formula 1, CaF 2 and MnO are low-melting point chemical components, O and CaO and MgO are high-melting point chemical components. That is, the ratio of the sum of CaF 2 and MnO to the sum of CaO and MgO (wt%) affects the melting point and fluidity of the slag in the sintered flux for Ssubmerged arc welding in accordance with the present invention. As a result, N welding workability such as arc stability, slag detachability, bead shape, and so
(N
on, are largely affected. Therefore, it is possible to limit the range of values of Formula 1 to control a melting point and fluidity of the slag on the basis of an appropriate weight ratio between the low-melting point chemical components and the high-melting point chemical components, thereby obtaining good welding workability, good arc stability, slag detachability, bead shape, and so on, which is required in the present invention.
When the basicity expressed by Formula 1 as the weight ratio of lowmelting point chemical components to high-melting point chemical components is smaller than 2.0, the melting point and viscosity of the slag are excessively increased, thus deteriorating bead shape and slag detachability. In addition, pockmarks are likely to be generated. When the basicity is larger than arc stability is decreased, thus lowering the melting point of the slag and deteriorating slag detachability.
Therefore, in order to obtain sintered flux for submerged arc welding having good welding workability even during high-speed welding, the basicity(B) defined in the present invention should be in the range of 2.0-6.5.
In order to obtain welding workability, such as good arc stability, slag detachability, bead shape, and so on, as required in the present invention, the
IND
\O
Scompleted flux should have an appropriate particle size distribution. When the O flux has an inappropriate particle size distribution, arc protection is deteriorated the beads become rough, and defects such as pores and undercuts are likely generated.
SAn appropriate particle size distribution of the sintered flux for submerged N arc welding having the above chemical composition and the basicity may
(N
include 5.0wt% or less particles larger than 1.00mm, 90.0wt% or more particles of 0.20-1.00mm, and 5.0wt% or less particles smaller than 0.20mm.
When the flux particles larger than 1.00mm are more than 5.0wt%, a space between the particles becomes too large and arc protection is reduced, making the beads rough and readily forming pockmarks.
In addition, when the flux particles of 0.20-1.00mm are less than 90.0wt%, convex beads are generated and bead grains become rough.
Finally, when the flux particles smaller than 0.20mm are more than since gas generated during the submerged arc welding is insufficiently discharged, pockmarks are generated and pits are likely generated. In addition, slag detachability is also deteriorated.
Specific welding characteristics of the flux in accordance with the present invention will be understood through the following embodiments.
Hereinafter, exemplary embodiments of the present invention will be described in detail, but the following description is not intended to limit the invention in any way.
Flux samples having the chemical compositions and basicities listed in the following Table 1 were manufactured. After distributing particles of the flux compositions into a water glass, the water glass was dried and sintered to obtain sintered flux for submerged arc welding having the compositions listed below.
Table 1 I Flux composition, wt% I I I I I I Na20O, Zr2, I
K
2 0, or I BaO, and Classification Si02 A1 2 0 3 TiO 2 CaO CaF 2 MnO MgO Li20, or mixture thereof FeO mixture thereof Sum *IE 1 12.0 32.5 10.0 4.0 14.0 18.0 8.0 1.0 0.5 100.0 5.3 IE 2 14.5 27.0 6.0 9.0 10.0 23.0 7.5 2.5 0.5 100.0 IE3 21.5 29.0 6.5 5.0 7.0 15.5 12.0 3.0 0.5 100.0 2.6 IE4 13.0 24.0 8.5 7.0 13.0 16.5 14.0 3.5 0.5 100.0 2.8 IE 5 20.0 30.0 9.0 4.5 9.0 20.0 5.0 1..5 1.0 100.0 6.1 IE6 24.0 28.5 9.5 3.0 8.5 15.0 6.0 4.0 1.5 100.0 5.2 IE7 19.0 26.0 13.0 2.0 8.5 12.0 17.0 2.0 0.5 100.0 2.2 IE 8 17.0 38.0 8.0 8.0 7.5 13.0 2.0 5.0 1.5 100.0 4.1 IE 9 23.0 29.0 7.5 3.0 8.0 18.5 9.0 1.5 0.5 100.0 4.4 *CE 1 26.0 24.0 7.0 1.0 10.0 21.5 8.0 2.0 0.5 100.0 CE2 20.0 40.0 10.0 5.5 7.0 8.0 6.0 2.5 1.0 100.0 2.6 CE3 13.5 25.5 15.0 3.5 11.5 19.5 10.0 0.5 1.0 100.0 4.6 CE4 10.0 35.0 6.0 7.5 12.0 20.0 6.0 2.0 1.5 100.0 4.7 15.0 29.5 8.0 4.0 4.5 26.0 11.5 1.0 0.5 100.0 3.9 CE 6 21.020.0 12.011.09.0 14.0|7.5 4.5 1.01o00.01.5 CE 7 12.026.0 8.5 4.0 8.5 15.024.5 1.0 0.5100.01.6 CE8 17.527.5 3.0 6.0 9.5 16.5 12.0 7.0 1.0100.02.9 CE9 18.025.0 7.0 4.5 17.023.0 1.0 4.0 0.5100.014.5 *IE Invention example, *CE Comparative example Welding of a welding wire of Table 3 below to a base metal of Table 2 below was performed using the flux compositions listed in Table 1.
Welding conditions are listed in Table 4 below, and welding workability evaluation results are arranged in Tables 5 to 7 below. Tables 5 to 7 list test results of welding workability at welding speeds of 100cm/min, 150cm/min, and 200cm/min, and the same polarity, current, and voltage. Symbols appearing in Tables 5 to 7 have the following meanings: o: good, normal, x: poor Table 2 Thickness Chemical composition of base metal, wt% Steel (mm) C Si Mn P S SM490 5 0.14 0.34 1.30 0.008 0.010 Table 3 Wire diameter Chemical composition of wire, wt% (mm) C Si Mn P S .8 0.06 0.31 1.10 0.018 0.008 Table 4 Polarity Current[A] Voltage[V ped]m/ n)Nt 1 2 '3 Bead on plate C750 34 100 150 200 elding Table Welding conditions: AC 750A-34V- 100cm/rnin.
Arc Pockmark jSlag Pit Bead Classification stability resistance Detachability resistance shape IEl1 0 0 0 0 1E2 0 0 0 0 0 1E3 0 0 0 0 0 IE4 0 0 0 0 0 0 0 00 0 IE6 0 0 0 0 0 IE7 0 0 0o 00 IE8 0 0 0 0 0 IE9 0 0 0 0 0 CEl 1 0 CE 2 0 0 0 0 CE3 0 0o 0 CE4 o 0 0 0 CE 60jo0 CE 7 0 CE 8 00 CE 9 X0 Table 6 Welding conditions: AC 750A-34V-1 Arc Pockmark 'Slag Pit lBead Classification stability resistance Detachability resistance shape IEl1 0 0 0 0 0 IE2 0 0 0 0 0 IE3 0 0 0 0 0 IE4 0 0 0 0 0 0 0 0 00 IE6 0 0 0 0 0 IE7 0 0 0 0 0 IE8 !0 0 0 0 0 IE9 0o 0 0 0 0 CEl 0 x 0 CE 2 CE 3 0 0 CE4 0 0 0x CE 5 0 0 CE 6 0 1 0 0 CE 7 0Ix Welding conditions: AC 750A-34V-200cm/min.
CE 6 0 X 0 0 x CE7 o x x CE8 x o x o CE9 x x x o Referring to Tables 5 to 7, it will be appreciated that the Exemplary Embodiments of the present invention have good welding workability, arc stability, pockmark resistance, slag detachability, pit resistance, bead shape, and so on, even when welding speed is increased.
Meanwhile, in the case of Comparative Example 1, since Si0 2 content is higher than the range of the present invention, CaO content is lower than the range of the present invention, and the basicity(B) as defined herein is higher than the range of the present invention, Table 5 does not list good results in arc stability, pockmark resistance, slag detachability, and bead shape at a welding speed of 100cm/min. In addition, Table 6 shows that when welding speed is increased to 150cm/min, pockmark resistance and slag detachability are further deteriorated. And, Table 7 shows that when welding speed is further increased to 200cm/min, arc stability is also deteriorated.
In the case of Comparative Example 2, since A1 2 0 3 content is higher than the range of the present invention, and MnO content is lower than the range of the present invention, Table 5 does not list good results for bead shape at a welding speed of 100cm/min. Moreover, Table 6 shows that when welding speed is increased to 150cm/min, slag detachability becomes poor, and Table 7
\O
Sindicates that when welding speed is further increased to 200cm/min, bead o shape further deteriorates.
In the case of Comparative Example 3, since TiO 2 content is higher than the range of the present invention, and content of Na20, K 2 0, Li 2 0, or a mixture t' thereof is lower than the range of the present invention, Table 5 does not list C good results for arc stability and bead shape at a welding speed of 100cm/min.
(N
In addition, Table 6 shows that when welding speed is increased to 150cm/min, bead shape results are poor, and Table 7 indicates that when welding speed is further increased to 200cm/min, arc stability deteriorates.
In the case of Comparative Example 4, since SiO 2 content is lower than the range of the present invention, Table 5 does not list good results for bead shape at a welding speed of 100cm/min. In addition, Table 6 shows that when welding speed is increased to 150cm/min, bead shape results are poor, and Table 7 indicates that when welding speed is further increased to 200cm/min, bead shape remains poor.
In the case of Comparative Example 5, since CaF 2 content is lower than the range of the present invention, and MnO content is higher than the range of the present invention, Table 5 does not list good results for pockmark resistance, slag detachability, and bead shape at a welding speed of 100cm/min. Further, Table 6 shows that when welding speed is increased to 150cm/min, slag detachability further deteriorates, and Table 7 indicates that when welding speed is further increased to 200cm/min, bead shape deteriorates.
In the case of Comparative Example 6, since A1 2 0 3 content is lower than the range of the present invention, and CaO content is higher than the range of
\O
Sthe present invention, Table 5 does not list good results for pockmark resistance, o and bead shape at a welding speed of 100cm/min. In addition, Table 6 shows that when welding speed is increased to 150cm/min, pockmark resistance is poor, and Table 7 indicates that when welding speed is further increased to t' 200cm/min, bead shape also deteriorates.
C In the case of Comparative Example 7, since MgO content is higher
\O
(N
than the range of the present invention, and basicity(B) as defined herein is lower than the range of the present invention, Table 5 does not list good results for pockmark resistance, slag detachability, and bead shape at a welding speed of 100cm/min. In addition, Table 6 shows that when welding speed is increased to 150cm/min, pockmark resistance is poor, and Table 7 indicates that when welding speed is further increased to 200cm/min, pit resistance and bead shape deteriorate.
In the case of Comparative Example 8, since TiO 2 content is lower than the range of the present invention, and content of Na 2 0, K 2 0, Li 2 0, or a mixture thereof is higher than the range of the present invention, Table 5 does not list good results for arc stability, slag detachability, and pit resistance at a welding speed of 100cm/min. In addition, Table 6 shows that when welding speed is increased to 150cm/min, slag detachability is poor, and Table 7 indicates that when welding speed is further increased to 200cm/min, arc stability deteriorates.
In the case of Comparative Example 9, since CaF 2 content is higher than the range of the present invention, MgO content is lower than the range of the present invention, and basicity(B) as defined herein is higher than the range of the present invention, Table 5 does not list good results for arc stability, slag detachability, bead shape, and pockmark resistance at a welding speed of 100cm/min. In addition, Table 6 shows that when welding speed is increased to 150cm/min, arc stability is poor, and Table 7 indicates that when welding speed is further increased to 200cm/min, slag detachability deteriorates.
The sintered flux for submerged arc welding of Exemplary Embodiment 1 of Table 1, whose basicity satisfies 2.0 B 2(CaF2+MnO)/(CaO+MgO) was divided into eight flux particle size distributions listed in Table 8.
Welding workability evaluation results of the sintered flux for submerged arc welding having the particle size distributions of Table 8 are listed in Table 9.
Welding conditions were AC 750A-34V-100cm/min.
Symbols used in Table 9 have the following meanings: o: good, normal, x: poor.
Table 8 Particle size distribution, wt% Classification 1.00mm or more 1.00mm 0.20mm 0.20mm or less Sum IE 10 5.0 90.0 5.0 100.0 IE 11 1 .0.0 4.0 100.0 IE 12 4.0 95.5 0.5 100.0 IE 13 3.0 93.0 4.0 100.0 CE 10 .0 91.0 3.0 100.0 CE11 2.5 90.5 7.0 100.0
IO
CE 12 10.0 85.0 5.0 100.0 o CE13 5.0 80.0 15.0 100.0 S Table 9 Arc Pockmark Slag Pit Bead 0 Classification Stability resistance detachability resistance shape SIE 10 0 0 00 0 O IE l o 0o 0 0 0 IE 12 0 0 o 0 0 CE 10 X X 0 CE 11 0 X 0 X 0 CE12 x x x o x CE13 CE13 o x ix x x Referring to Tables 8 and 9, it will be appreciated that the present invention provides good arc stability, pockmark resistance, slag detachability, pit resistance, and bead shape when the sintered flux for submerged arc welding includes 5.0wt% or less particles larger than 1.00mm, 90.0wt% or more particles of 0.20-1.00mm, and 5.0wt% or less particles smaller than 0.20mm.
Meanwhile, in the case of Comparative Example 10 of Table 8, since the content of particles larger than 1.00mm is higher than the range of the present invention, Table 9 shows poor results for arc stability, pockmark resistance, and bead shape.
\O
SIn the case of Comparative Example 11 of Table 8, since the content of O particles smaller than 0.20mm is higher than the range of the present invention, Table 9 shows poor results for pockmark resistance and pit resistance.
In the case of Comparative Example 12 of Table 8, since the content of particles larger than 1.0mm is higher than the range of the present invention, N and the content of particles of 0.20mm-i.00mm is lower than the range of the
(N
0present invention, Table 9 lists poor results for arc stability, pockmark resistance, slag detachability, and bead shape.
In the case of Comparative Example 13 of Table 8, since the content of particles of 0.20mm-i.00mm is lower than the range of the present invention, and the content of particles smaller than 0.20mm is higher than the range of the present invention, Table 9 lists poor results for the pockmark resistance, slag detachability, pit resistance, and bead shape.
As can be seen from the foregoing, the present invention provides a chemical composition used in sintered flux for submerged arc welding whose basicity (B) 2(Ca F 2 +MnO) satisfies 2.0 CaQ+MgO 5 6.5, and which includes 5.0wt% or less particles larger than 1.00mm, 90.0wt% or more particles of 0.20-1.00mm, and 5.0wt% or less particles smaller than 0.20mm. Accordingly, it is possible to obtain sintered flux for submerged arc welding having good welding workability, arc stability, pockmark resistance, slag detachability, pit resistance, and bead shape, even when welding speed is increased.
Although the present invention has been described with reference to 0 Scertain exemplary embodiments thereof, it will be understood by those skilled in o the art that a variety of modifications and variations may be made to the present 0 invention without departing from the spirit or scope of the present invention defined in the appended claims, and their equivalents.
Claims (2)
1. Sintered flux for submerged arc welding consisting of: 12.0-24.0wt% SiO 2
24.0-38.0wt%, A1 2 0 3 6.0-13.0wt% TiO 2 2.0-9.0wt% CaO, 7.0-14.0wt% CaF 2 12.0- 23.0wt% MnO, 2.0-17.0wt% MgO, 1.0-5.0wt% Na20, K20, Li 2 0 or a mixture thereof, and 0.5-1.5wt% a mixture of ZrO 2 BaO, and FeO. C1 2. The sintered flux for submerged arc welding according to claim 1, wherein C1 basicity of the sintered flux satisfies the following Formula 1: O S[Formula 1] 2(CaF +MnO) s CaO+MgO 3. The sintered flux for submerged arc welding according claim 1 or 2, wherein the sintered flux for submerged arc welding comprises 5.0wt% or less particles larger than 1.00mm, 90.0wt% or more particles of 0.20-1.00mm, and 5.0wt% or less particles smaller than 0.20mm. 4. Sintered flux for submerged arc welding substantially as hereinbefore described with reference to Examples 1 to 13. 23
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| KR10-2005-0109937 | 2005-11-17 | ||
| KR1020050109937A KR100706026B1 (en) | 2005-11-17 | 2005-11-17 | Sintered Flux for Submerged Arc Welding with High Speed Weldability |
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| AU2006225236A1 AU2006225236A1 (en) | 2007-05-31 |
| AU2006225236B2 true AU2006225236B2 (en) | 2008-07-31 |
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| KR (1) | KR100706026B1 (en) |
| AU (1) | AU2006225236B2 (en) |
| EG (1) | EG24317A (en) |
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| CN109454361A (en) * | 2018-11-28 | 2019-03-12 | 东莞理工学院 | Low-hygroscopicity submerged-arc welding sintered flux and preparation method thereof |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| JP5334725B2 (en) | 2009-07-27 | 2013-11-06 | 株式会社神戸製鋼所 | Sintered flux for 9% Ni steel submerged arc welding |
| JP5415891B2 (en) | 2009-10-07 | 2014-02-12 | 株式会社神戸製鋼所 | Titanium oxide raw material for welding materials, flux cored wire, coated arc welding rod and flux for submerged arc welding |
| KR101340448B1 (en) * | 2011-12-22 | 2013-12-11 | 현대종합금속 주식회사 | Agglomerated flux for submerged arc welding |
| JP6104090B2 (en) * | 2013-08-05 | 2017-03-29 | 株式会社神戸製鋼所 | Submerged arc welding flux and manufacturing method thereof |
| JP6104146B2 (en) * | 2013-12-13 | 2017-03-29 | 株式会社神戸製鋼所 | Submerged arc welding flux and manufacturing method thereof |
| JP6737567B2 (en) * | 2015-02-02 | 2020-08-12 | 株式会社神戸製鋼所 | Submerged arc welding flux |
| KR101760829B1 (en) | 2016-03-25 | 2017-07-24 | 현대종합금속 주식회사 | Submerged arc welding flux for thin plate welding |
Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4338142A (en) * | 1980-06-27 | 1982-07-06 | Kobe Steel, Limited | Melting flux composition for submerged arc welding |
| JPS62270297A (en) * | 1986-05-20 | 1987-11-24 | Kawasaki Steel Corp | Fused flux for submerged arc welding |
| KR20020005302A (en) * | 2000-07-10 | 2002-01-17 | 이봉주 | Flux for using butt submerged arc welding |
| KR20040045994A (en) * | 2002-11-26 | 2004-06-05 | 고려용접봉 주식회사 | A flux composition for submerged arc welding |
-
2005
- 2005-11-17 KR KR1020050109937A patent/KR100706026B1/en active Active
-
2006
- 2006-10-04 IL IL178452A patent/IL178452A/en active IP Right Grant
- 2006-10-05 AU AU2006225236A patent/AU2006225236B2/en not_active Ceased
- 2006-11-13 SA SA06270412A patent/SA06270412B1/en unknown
- 2006-11-16 EG EG2006110596A patent/EG24317A/en active
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4338142A (en) * | 1980-06-27 | 1982-07-06 | Kobe Steel, Limited | Melting flux composition for submerged arc welding |
| JPS62270297A (en) * | 1986-05-20 | 1987-11-24 | Kawasaki Steel Corp | Fused flux for submerged arc welding |
| KR20020005302A (en) * | 2000-07-10 | 2002-01-17 | 이봉주 | Flux for using butt submerged arc welding |
| KR20040045994A (en) * | 2002-11-26 | 2004-06-05 | 고려용접봉 주식회사 | A flux composition for submerged arc welding |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN109454361A (en) * | 2018-11-28 | 2019-03-12 | 东莞理工学院 | Low-hygroscopicity submerged-arc welding sintered flux and preparation method thereof |
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| IL178452A0 (en) | 2008-01-20 |
| AU2006225236A1 (en) | 2007-05-31 |
| KR100706026B1 (en) | 2007-04-12 |
| IL178452A (en) | 2011-08-31 |
| SA06270412B1 (en) | 2010-06-28 |
| EG24317A (en) | 2009-01-20 |
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