Article
Engineering, Chemical
Jin Zhang, Qiong Xu
Summary: This study investigates the element transfer behavior of Cr2O3-bearing agglomerated fluxes in submerged arc welding. The gas-slag-metal equilibrium consideration is shown to qualitatively analyze the transfer behaviors, and a thermodynamic approach to predict element transfer levels is proposed.
Article
Automation & Control Systems
Sumit Saini, Kulwant Singh
Summary: Recycled steel slag has been successfully used to produce submerged arc welding flux, improving the quality of the weld metal. By adding specific components to the recycled slag, the chemical composition of the weld metal can meet ASME specifications. The addition of recycled slag also enhances the strength and hardness of the weld, providing a cost-effective alternative to virgin flux in the market.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Engineering, Chemical
Jin Zhang, Dan Zhang
Summary: Submerged arc welding is a complex metallurgical process with temperatures exceeding 2000 degrees C. The variation of oxygen content in the metal during the welding process remains unclear. A thermodynamic approach based on Oxygen Layer Theory, Local Attained Equilibrium, and Scheil Solidification has been proposed to estimate the trend of oxygen content variation. The approach has shown to be effective in predicting the variation of oxygen content when using typical CaO-Al2O3 based fluxes and evaluating factors influencing oxygen content levels from a thermodynamic perspective.
Article
Engineering, Industrial
Mahdi Alishavandi, Mahdi Mohammadmirzaei, Mahnam Ebadi, Amir Hossein Kokabi
Summary: Bead-on-plate submerged arc welding was conducted on AISI 4135 heat-treatable low-alloy steel using S2 welding wire and granular Cr-Mo basic flux. The alloying elements were introduced into weld metal via an active flux. Two methods for calculating the recovery rate of alloying elements were introduced, and the specific amount of elements transferred from the flux into the weld metal was calculated. Various tests were performed to investigate microstructure evolutions, inclusion characteristics, mechanical properties, and fracture mechanisms of all weld metals.
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2021)
Article
Engineering, Chemical
Jin Zhang, Dan Zhang, Ping Liu
Summary: By analyzing the fluxes of 23 formulas, the thermodynamic interconnection between oxides (SiO2 and FeO) and the flux O potential was studied, aiming to clarify the controversial conclusions raised by different investigators. It was found that simulating the equilibrium FeO activity can effectively evaluate the flux potential for both acid and basic fluxes, which can potentially save experimental resources on flux design and analysis.
Article
Materials Science, Multidisciplinary
Byeong Chan Choi, Byoungkoo Kim, Byung Jun Kim, Yong-Wook Choi, Sang Joon Lee, Jong Bae Jeon, Yangdo Kim, Hyoung Chan Kim
Summary: This study investigated the low-temperature fracture behavior of an 80-mm-thick low-carbon steel plate welded by submerged arc. The relationship between impact absorbed energy and ductility-brittle transition temperature (DBTT) was evaluated based on microstructures, with acicular ferrite showing the highest resistance to low-temperature impact among various microstructures in the heat-affected zone.
Article
Materials Science, Multidisciplinary
Xiaobo Yuan, Yongwu Wu, Ming Zhong, Somnath Basu, Zhanjun Wang, Cong Wang
Summary: This study investigated inclusions in EH36 shipbuilding steel submerged arc welded with CaF2-TiO2 fluxes. The inclusions were found to be mainly of a complex Ti-containing type, with an increase in Ti content and a reduction in Al and Mn content with increasing TiO2 content. The size distribution of inclusions followed a log-normal pattern, with frequency peaks ranging from 0.3 to 0.4 μm. The number density and volume fraction of inclusions showed a definite increasing trend, which was attributed to the uptake of O from 110 to 210 ppm enabled by TiO2 decomposition.
SCIENCE AND TECHNOLOGY OF WELDING AND JOINING
(2022)
Article
Metallurgy & Metallurgical Engineering
Wang Cong, Zhang Jin
Summary: Flux is essential for submerged arc welding and plays a crucial role in determining the final composition of weld metal through complex chemical reactions. Recent progress has been made in studying the control mechanisms of flux on submerged arc welded metal compositions, including element transfer behaviors and the limitations of compositional prediction models. Fundamental challenges for further exploration in this field are discussed.
ACTA METALLURGICA SINICA
(2021)
Article
Materials Science, Ceramics
Zhanjun Wang, Xiaorui Zheng, Ming Zhong, Zushu Li, Cong Wang
Summary: This study systematically investigated the crystallization behaviors of CaF2-TiO2 fluxes with varying TiO2 contents. It was found that the TiO2 content of 30 wt.% exhibited the highest barrier to crystallize and the highest capability to achieve the most desired production of amorphous welding fluxes for high heat input applications.
JOURNAL OF NON-CRYSTALLINE SOLIDS
(2022)
Article
Materials Science, Multidisciplinary
Mingxu Sun, Sihua Liu, Yuanyuan Cheng, Zhi Cheng, Ruiming Ren, Chunhuan Chen
Summary: The feasibility of interrupted pulsed argon arc welding (IPAW) for 0.5 mm-thick AISI 430 ferritic stainless steel (FSS) was studied. Two different joining modes were observed under different welding parameters. The joints exhibited higher microhardness in the fusion zone (FZ) and heat-affected zone (HAZ). The tensile strength of the joints with a typical fusion pool structure was lower due to weak bonding between columnar grains, while joints with a snowflake-shaped structure displayed higher tensile strength due to random intergranular bonding interfaces.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2022)
Article
Thermodynamics
Jin Zhang, Guoyou Shao, Yan Guo, Qiong Xu, Zhongqiu Liu
Summary: This study utilizes thermodynamic software FactSage to aid in flux design and conducts experiments to verify its effectiveness. The results demonstrate that the thermodynamic approach can facilitate the flux design process and evaluate elemental transfer mechanisms.
CALPHAD-COMPUTER COUPLING OF PHASE DIAGRAMS AND THERMOCHEMISTRY
(2022)
Article
Materials Science, Multidisciplinary
Chao Chen, Guorui Sun, Wenbo Du, Yue Li, Chenglei Fan, Huijing Zhang
Summary: This study achieved the same heat input by designing different combinations of welding parameters and analyzed the formation, microstructure, and mechanical properties of the weld bead. The results showed that under the same heat input, the welding current and voltage had a significant impact on the weld bead, affecting its penetration, width, spreadability, and hardness.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2022)
Article
Materials Science, Ceramics
Jin Zhang, Li Wang
Summary: Fluxes play important roles in atmospheric shielding, arc stabilization, and weld metal composition control during submerged arc welding process. Mn content control is critical for weldment toughness. This study aims to upgrade the slag-metal equilibrium model to the gas-slag-metal equilibrium model using CALPHAD technology to compensate for the limitations of the former. Both slag-metal and gas-slag-metal equilibrium models were used to predict Mn content in weld metal. The gas-slag-metal equilibrium model showed higher prediction accuracy and the capability to predict Mn transfer even without initial MnO.
CERAMICS INTERNATIONAL
(2023)
Article
Engineering, Mechanical
Sumit Saini, Kulwant Singh
Summary: The steel-making plant's slag has been utilized to produce essential flux for submerged arc welding process. The researchers have investigated the effect of welding conditions and flux composition on element transfer behavior. Mathematical models were developed using the data generated during experimentation and tested for adequacy. The study revealed that the slag provided acceptable weld metal chemistry and that welding current and travel speed significantly influenced the carbon and manganese content in the weld metal.
PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART E-JOURNAL OF PROCESS MECHANICAL ENGINEERING
(2023)
Article
Engineering, Chemical
Theresa Coetsee, Frederik De Bruin
Summary: The study discusses the use of Al, Ti, and Cu powder in submerged arc welding of carbon steel, finding that Cu powder can improve the efficiency of Ti transfer to the weld metal, further improving the composition of the weld metal.
Article
Engineering, Manufacturing
Sandeep Jindal, Rahul Chhibber, Narinder P. Mehta
PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART B-JOURNAL OF ENGINEERING MANUFACTURE
(2014)
Article
Engineering, Manufacturing
Sandeep Jindal, Rahul Chhibber, N. P. Mehta
PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART B-JOURNAL OF ENGINEERING MANUFACTURE
(2013)
Article
Engineering, Manufacturing
Sandeep Jindal, Rahul Chhibber, Narinder P. Mehta
PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART B-JOURNAL OF ENGINEERING MANUFACTURE
(2014)
Article
Materials Science, Multidisciplinary
Sandeep Jindal, Harpreet Singh
Summary: Submerged arc welding was conducted on duplex stainless steel plates using a slag-fresh flux mixture. The composition variation of the mixture was quantitatively studied to investigate its effects on weld bead geometry parameters. Using the Scheffe Quadratic Model and desirability approach, the composition of the slag-fresh flux mixture was optimized for weld bead characteristics.
JOURNAL OF THE MECHANICAL BEHAVIOR OF MATERIALS
(2021)
Proceedings Paper
Materials Science, Multidisciplinary
Sandeep Jindal, Rahul Chhibber, N. P. Mehta
EUROPEAN SYMPOSIUM ON MARTENSITIC TRANSFORMATIONS
(2013)
Proceedings Paper
Materials Science, Multidisciplinary
Sandeep Jindal, Rahul Chhibber, N. P. Mehta
FUTURE MATERIALS ENGINEERING AND INDUSTRY APPLICATION
(2012)