The Effect of Welding Consumables on Arc Welding Process Control and Weld Metal Structure and Properties

Abstract

Abstract : The effect of welding consumables on arc welding process control and weld metal structure and properties was investigated. The first study demonstrated the potential use of exothermically (thermite) assisting steel arc welding consumables for field repair welding. Both shielded metal arc (SMA) and flux cored arc (FCA) consumables were prepared to allow generation of chemical energy to supplement electrical energy during welding, allowing for welding with smaller or even no external power sources. Work is in progress to make these consumables both exothermic and self-shielding. These research studies continued with issues related to weld metal microstructure control. Weld metal aluminum grain refining is being investigated to improve the weldability of aluminum alloys, Grain refiners, which are being introduced through the metal cored welding consumables, were selected based on an understanding of the innoculant dissolution kinetics, and weld metal solidification behavior. Also, the role of shielding gas oxygen on the welding pool chemistry was studied. Finally, a project demonstrating the ability to use magnetic measurements to monitor weld metal phase changes was performed.