The effect of flux chemistry on element transfer in Submerged Arc Welding: application of thermochemical modelling

Abstract

Post-weld slag and weld metal analyses were used to interpret the effects of different commercial flux compositions on element transfer between molten flux (slag) and weld metal in Submerged Arc Welding (SAW). Selected fluoride based flux compositions cover a wide range of basicity index (BI) values of 0.5–3.0. Thermochemical modelling in FactSage software is used to simulate the welding process in terms of gas-slag-metal equilibria. The importance of the gas phase in SAW element transfer is illustrated. The model provides improved accuracy in predicted weld metal oxygen values (ppm O) compared to the generally used empirical relationship of weld metal ppm O vs. flux BI. Model predicted oxygen values are within 150 ppm of the analysed values, compared to the empirical relationship values which are within 240 ppm from the analysed values. The model provides resolution in ppm O values at BI > 1.8. This information is lacking in the empirical relationship with constant ppm O of 250 ppm at BI > 1.8. The measured ppm O values follow the Fe–FeO equilibrium trend with a positive offset. The relative level of oxygen to deoxidation elements (Ti, Al, Mn, Si) in the weld metal is an important factor in oxide inclusion engineering. This model will aid in the specification of flux formulations to attain specific weld metal compositions for maximum acicular ferrite formation. In this way the weld metal mechanical properties can be improved. This model will reduce the number of welding tests required to develop new flux formulations.