Abstract
Received 5 May 2009, in revised form 6 August 2009 Abstract. A granular flux, which is used in submerged arc welding, plays an important role in deciding the weld metal quality and it may cost up to half of the total welding consumable cost. A significant percentage of the flux gets converted into very fine particles, termed as flux dust, due to transportation and handling. Welding defects like porosity occur if welding is performed without removing these very fine particles from the flux, and if these fine particles are removed by sieving, the cost of welding will be increased significantly . Also if this flux dust is dumped, it creates pollution. The present study has been conducted to investigate the viability of developing an acidic agglomerated flux by utilizing wasted flux dust of the parent commercial acidic flux. The chemical composition and mechanical properties of the all-weld metal, prepared by using the developed acidic flux, were found to be in the same range as that of the weld metal, prepared from parent commercial acidic flux. The radiographic examination of the welded joint, made by developing the flux, was also found to be sound. Therefore the welding cost and pollution can be reduced, without any compromise in weld quality, by utilizing the developed flux, prepared from waste flux dust of the parent flux. Thus the work follows the concept of 'waste to wealth'.
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