Investigation of characteristic of powder wire with the CuO / AL exothermic mixture

Abstract

The paper the results of research is presented and the level of influence of the parameters of surfacing and the amount of exothermic mixture in the composition of self-shielding flux-cored wire on the deposition rate factor and spattering factor are analyzed. The analysis of the experiment was performed using the Taguchi method, in addition, to determine the influence of individual factors on the studied parameters (ad, ψS), analysis of variance (ANOVA) is fulfilled. It was found that for the deposition rate factor, according to the degree of influence the factors are distributed in the following order − WFS, B, CTWD, Ua, and for the spattering factor − Ua, B, CTWD, WFS. According the analysis of variance (ANOVA) of the experiment results are determined that the greatest impact on the deposition rate factor (ad) has the wire feed speed (WFS − 53.98%), the amount of exothermic mixture in the core of flux-cored wire (B − 27.3%) and contact tip to work distance (CTWD − 22.75%) have less influence, and the influence of the arc voltage (Ua) can be neglected since its contribution is only 5.82%. The arc voltage (Ua) has a high influence on the spattering factor (ψS), whose contribution is more than half (60.19%), the amount of exothermic mixture in the charge of flux-cored wire (B) has less influence, whose influence is (22.38%), while contact tip to work distance (CTWD) and wire feed speed (WFS) have minor influence and are respectively 11.55% and 5.88%. Technologically acceptable modes of surfacing are determined (contact tip to work distance CTWD = 35 mm; flux-cored wire feed speed WFS = 124 m / h; arc voltage Ua = 28V) and amount of exothermic mixture in the core of flux-cored wire, which significantly influences on the indexes of deposition rate factor and spattering factor. Models of the 2nd order of dependence on the two most significant factors for the indexes аn and ψр are constructed.

Comparison of two-body abrasive wear resistance of high chromium boron-containing Fe–C B–13wt.%Cr Ti alloy with incomplete replacement of Cr for Cu the Fe C B 4wt.%Cr 7wt.%Cu–Ti alloy

“…Weld deposition were realized as three-layered to minimize impact of mixing the layer with base material. Welding parameters where chosen to provide high deposition values (high deposition rate and low spattering factor) [16], as well as for low solution of the deposited metal with the base metal and providing welded bead optimal shape [17]. Thus, hardfacing was performed by FCAW-S were as follows: wire feed speed WFS=1.85 m/min, arc welding voltage Ua =28 V, travel speed TS=0.3 m/min, contact tip to work distance CTWD=45 mm, DCRP Polarity, temperature preheating Tp=250…300 °C.…”

Effect of Exothermic Addition (CuO - Al) on the Structure, Mechanical Properties and Abrasive Wear Resistance of the Deposited Metal During Self-Shielded Flux-Cored Arc Welding

“…Improving productivity and energy efficiency is one of the main challenges for developers of welding and surfacing filler materials. One of the promising methods for increasing energy efficiency (reducing energy consumption) and increasing the productivity of FCAW-S is the introduction of an exothermic addition into the core filler of a flux-cored wire electrode [45][46][47][48][49]. Recent studies of the author have shown the effectiveness of the desired copper content provision due to introduction of exothermic addition CuO -Al [48,50].…”

“…Weld deposition were realized as three-layered to minimize impact of mixing the layer with base material. Welding parameters where chosen to provide high deposition values (high deposition rate and low spattering factor) [45,47], as well as for low solution of the deposited metal with the base metal and providing welded bead optimal shape [48,49]. Thus, hardfacing was performed by FCAW-S according to the parameters are shown in Table 3.…”