Abstract
Shielded-metal arc, submerged arc, and flux-cored arc welding processes (1) all rely on a flux to achieve an acceptable weld deposit. The welding flux for each of these processes must meet specific physical and chemical requirements to perform properly (2). A flux must have a melting range such that the weld metal solidifies before the molten slag does, and the resulting slag must have a density such that it floats to the top of the weld pool and collects there. The specific ranges of melting and density vary depending on the alloy being welded. The flux must also assist in main taining the arc plasma, in producing a shielding gas to protect the weld deposit from the atmosphere, and in limiting the amount of splatter. The flux viscosity is important because it controls the extent to which the flux can chemically alter the weld-metal composition, and it influences weld metal porosity, bead morphology, and the ability to make out-of-position weld deposits (3, 4). The flux must contain specific chemical additions to influence the weld metal's composition, microstructure, and properties.
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