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

Lozynskyi, Vasyl; Trembach, Bohdan; Hossain, Md Mukter; Kabir, Mohammad Humaun; Silchenko, Yury; Krbata, Michal; Sadovyi, Kostiantyn; Kolomiitse, Oleksii; Ropyak, Liubomyr

doi:10.1016/j.heliyon.2024.e25199

Cited by 14 publications

(7 citation statements)

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“…However, the most widespread application is found in the welding process [25]. Based on type, this application is classified into stick electrodes, solid wires, flux-cored wires, and submerged arc welding (SAW) wires with fluxes [26]. The flux-cored arc welding process is increasingly used in many industries, including construction, automobile production, agriculture, mining, etc.…”

Section: Introductionmentioning

confidence: 99%

“…In this case, it is of great interest to improve the energy efficiency of the welding process and the quality of the deposited metal. One of the most promising ways to improve the energy efficiency of the welding and hardfacing processes is the introduction of exothermic addition to the core filler [26,66]. Additional heat is generated at the electrode tip or in the welding arc by an exothermic reaction.…”

Section: Introductionmentioning

confidence: 99%

“…In self-shielded flux-cored wire arc welding with exothermic addition, the welding current is determined not only by the wire feed speed (WFS) but also by the exothermic addition used and its amount (EA) in the core filler [26,61], as well as the contact tip to work distance (CTWD) and set arc welding (U set ) [61,76]. The first parameter is determined by the characteristics of the power supply.…”

Section: Introductionmentioning

confidence: 99%

“…In such cases, it is advisable to consider alternative exothermic addition systems [61]. For hardfacing, alloys from the Fe-C-B-Cr-Cg-Cu system [26,27,83] are of particular interest, especially when additionally alloyed with a significant amount of copper. The high degree of copper alloying improves the microstructure of the deposited metal, enhances its mechanical properties and resistance to abrasive wear [26], and significantly increases corrosion resistance [27].…”

Section: Introductionmentioning

confidence: 99%

“…For hardfacing, alloys from the Fe-C-B-Cr-Cg-Cu system [26,27,83] are of particular interest, especially when additionally alloyed with a significant amount of copper. The high degree of copper alloying improves the microstructure of the deposited metal, enhances its mechanical properties and resistance to abrasive wear [26], and significantly increases corrosion resistance [27]. Trembach et al [64] first proposed the use of exothermic addition CuO-Al for hardfacing processes.…”

Section: Introductionmentioning

confidence: 99%

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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

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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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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%