Prediction of Fill Factor and Charge Density of Self-Shielding Flux-Cored Wire with Variable Composition

Trembach, B. O.; Hlushkova, D. V.; Hvozdetskyi, V. M.; Vynar, V. A.; Zakiev, V. I.; Kabatskyi, O. V.; Savenok, D. V.; Zakavorotnyi, O. Yu.

doi:10.1007/s11003-023-00738-7

Cited by 10 publications

(9 citation statements)

References 18 publications

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“…The indentation test parameters used in this work are presented in Table 3 . Samples were cut from welded plates according to the procedure presented in the work [ 48 ].…”

Section: Methodsmentioning

confidence: 99%

“…The following welding techniques are widely implemented in practice [ 39 , 40 ]: shielded metal arc welding (SMAW) [ 41 , 42 ], gas tungsten arc welding (GTAW [ 43 , 44 ] or TIG) [ 45 , 46 ], gas metal arc welding (GMAW or MIG), submerged arc welding (SAW), manual metal arc welding (MMA or MMAW) and flux-cored arc welding (FCAW) [ 2 , 14 , [47] , [48] , [49] , [50] , [51] ]. Self-shielded flux-cored wires arc welding (FCAW–S) is more environmentally friendly and more energy efficiency [ 52 ], higher productivity, high quality of the deposited metal, high deposition rate, arc visibility [ 41 , 48 , 49 ]. The flux cored wires segment is the most significant by type segment in the global market, and is expected to be the first preference [ 52 ].…”

Section: Introductionmentioning

confidence: 99%

“…as well as the required quality of the deposited metal [ [108] , [109] , [110] , [111] , [112] ]. Many researchers propose the introduction of an exothermic addition into welding materials [ 2 , 48 , 52 , [113] , [114] , [115] , [116] ]. as a solution for the energy efficiency and productivity increasing.…”

Section: Introductionmentioning

confidence: 99%

“…It allowed to reduce a consumption of electricity used for welding materials melting due to a chemical heat generation. According to research, an introduction of exothermic addition in the core filler is an effective measure to improve the uniformity of flux-cored wire melting [ 48 , 117 , 118 ]. Besides, the introduction of an exothermic addition increases the deposition rate [ 49 ], improves the morphology of the weld bead [ 51 , 119 ], arc process efficiency [ 119 ] and the hardfacing process stability [ 120 ].…”

Section: Introductionmentioning

confidence: 99%

See 3 more Smart Citations

Prediction of phase composition and mechanical properties Fe–Cr–C–B–Ti–Cu hardfacing alloys: Modeling and experimental Validations

Lozynskyi,

Trembach,

Hossain

et al. 2024

Heliyon

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“…The indentation test parameters used in this work are presented in Table 3 . Samples were cut from welded plates according to the procedure presented in the work [ 48 ].…”

Section: Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Prediction of phase composition and mechanical properties Fe–Cr–C–B–Ti–Cu hardfacing alloys: Modeling and experimental Validations

Lozynskyi,

Trembach,

Hossain

et al. 2024

Heliyon

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“…This preheating enables the electrode to burn off faster and increases the deposition rate [77]. It has been concluded that the welding consumables, welding parameters, and equipment have a key role to play in the stability of the welding process [78][79][80][81].…”

Section: Introductionmentioning

confidence: 99%

Effect of Exothermic Additions in Core Filler on Arc Stability and Microstructure during Self-Shielded, Flux-Cored Arc Welding

Lozynskyi,

Trembach,

Katinas

et al. 2024

Crystals

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In the conditions of an energy crisis, an important issue is the increase in energy efficiency and productivity of welding and hardfacing processes. The article substantiates the perspective of using exothermic additives introduced into core filler for flux-cored wire arc welding processes as a relatively cheap additional heat source, reducing energy consumption when melting filler materials, and increasing the deposition rate. The mixture design (MD) was selected as the design method to optimize the average values of current and voltage, as well as arc stability parameters depending on core filler composition. This article studies the influence of the introduction of exothermic addition (EA), as well as the ratios CuO/C and CuO/Al on arc stability for the FCAW S process. Parameters characterizing arc stability were determined using an oscillograph, and from the obtained oscillograms, an analysis was conducted on arc voltage and welding current signals during flux-cored arc welding. It was determined that various methods can be used to evaluate arc stability, which can be divided into two groups: graphical (current and voltage cyclograms, box plots with frequency histograms, ellipse parameters plotted on current, and voltage cyclograms) and statistical (standard variation and coefficients of variation for welding current and arc voltage). In this paper, a comprehensive evaluation of arc stability depending on the composition of the cored wire filler was carried out. It was determined that the most stable current parameters were observed for the flux-cored wire electrode with an average exothermic addition content at the level of EA = 26.5–28.58 wt.% and a high carbon content (low values of CuO/C = 3.75). Conversely, the lowest values of arc stability (CV(U) and Std(U)) were observed during hardfacing with a flux-cored wire electrode with a high CuO/Al ratio ≥ 4.5 and a content of exothermic addition in the core filler below the average EA < 29 wt.%. Mathematical models of mean values, standard deviation, coefficient of variation for welding current, and arc voltage were developed. The results indicated that the response surface prediction models had good accuracy and prediction ability. The developed mathematical models showed that the ratio of oxidizing agent to reducing agent in the composition of exothermic addition (CuO/Al) had the greatest influence on the welding current and arc voltage characteristics under investigation. The percentage of exothermic mixture in the core filler (EA) only affected the average welding current (Iaw) and the average arc voltage (Uaw). The graphite content expressed through the CuO/C ratio had a significant impact on welding current parameters as well as the coefficient of variation of arc voltage (CV(U)). Two welding parameters were selected for optimization: the mean welding current (Iaw) and the standard deviation of arc voltage (Std(U)). The best arc stability when using exothermic addition CuO-Al in the core filler was observed at CuO/Al = 3.6–3.9, CuO/C = 3.5–4.26, and at an average EA content of 29–38 wt.%. The significant influence of the CuO/Al and CuO/C ratios on arc voltage parameters can also be explained by their impact on the elemental composition of the welding arc (copper, cupric oxide (CuO), and Al2O3). The more complete this reaction, the higher the amount of easily vaporized copper (Cu) in the arc plasma, enhancing arc stability. The influence of core filler composition on the microstructure of deposited metal of the Fe-Cr-Cu-Ti alloy system was investigated.

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Study of the hardfacing process using self-shielding flux-cored wire with an exothermic addition with a combined oxidizer of the Al-(CuO/Fe2O3) system

Trembach,

Silchenko,

Balenko

et al. 2024

Int J Adv Manuf Technol

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Prediction of Fill Factor and Charge Density of Self-Shielding Flux-Cored Wire with Variable Composition

Cited by 10 publications

References 18 publications

Prediction of phase composition and mechanical properties Fe–Cr–C–B–Ti–Cu hardfacing alloys: Modeling and experimental Validations

Prediction of phase composition and mechanical properties Fe–Cr–C–B–Ti–Cu hardfacing alloys: Modeling and experimental Validations

Effect of Exothermic Additions in Core Filler on Arc Stability and Microstructure during Self-Shielded, Flux-Cored Arc Welding

Study of the hardfacing process using self-shielding flux-cored wire with an exothermic addition with a combined oxidizer of the Al-(CuO/Fe2O3) system

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