Melting Behavior of a CaO–SiO₂–Al₂O₃ Flux with Varying MnO Concentration for Use in Fusion Welding of Low‐Carbon Steel

Abstract

CaF2 has been a very common constituent in the fluxes used for welding of low‐carbon steel plates, owing to its strong ability to lower the liquidus temperature as well as viscosity of the molten flux. But the adverse impact of fluoride evaporation from molten slag on the health of operating personnel and the environment has prompted a worldwide effort to replace CaF2 with more benign constituents. Three compositions with varying MnO concentration in the CaO–MnO–SiO2–Al2O3 system, identified in the current work, have shown promise in terms of ability to control oxygen transfer and modify inclusion generation in the molten metal during the welding of low carbon low alloy steels. However, the melting behavior of a flux needs to be established before recommending its use for welding. Three compositions, with varying MnO concentration, are chosen in the current work. Aided by experimental measurements using high‐temperature microscopy, DTA and simulations using the commercially available thermodynamic package FactSage (version 8.3), this work aims to understand the melting characteristics of the developed fluxes. These characteristics seem to be comparable with a commercial CaF2‐containing welding flux, used as a reference for comparison. In addition, simulations using FactSage suggest that transfer of dissolved O, Si and Mn to the weld metal, while using these fluxes, would be benefitial to performance of the welded joint.