Among the various types of fluxes use in Submerged Arc Welding are the fused flux and the bonded flux. Each of these fluxes offers some advantages and some disadvantages.
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When making fused fluxes, the raw materials are dry mixed together, and then they are fused or melted into a liquid state by using a high temperature furnace. After fusion is complete, the fluxes are cooled. This may be accomplished by using a stream of water or with big chill blocks.
Once the fluxes are cooled, they are crushed or ground into particles. A variety of particle sizes are made to ensure optimal performance for different applications.
Advantages of fused fluxes include:
The non-hygroscopic flux particles do not absorb moisture and, therefore, any surface moisture can be eliminated merely by drying the particles at a low temperature oven setting of 300 degrees F.
A disadvantage of fused fluxes is that the high temperature used during the manufacture process makes it difficult to add alloys and deoxidizers.
Bonded Fluxes
The manufacture of bonded fluxes involves combining the dry ingredients, then using a liquid binder such as sodium silicate or potassium silicate to glue the ingredients together. After the bonded mix is made into pellets, the pellets are baked at a low oven temperature. Once the drying of the pellets is complete, the pellets are broken up by using a sieve to attain the desired particle size. The particles are then packaged for shipping.
Advantages of bonded fluxes include:
There are at least two disadvantages of using bonded fluxes. These are:
References:
Miller Submerged Arc Welding
ESAB Welding and Cutting, U.S.
Rutile Electrodes:
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contain more than 50% rutile, providing a very stable arc. For gas shielding the electrode also contains some cellulose, along with deoxidizers, and arc stabilizers. As with the cellulosic electrodes, rutile types can be used in all positions, but the arc does not penetrate as deeply as the cellulosic type.This allows the weld to fill gaps more easily. A dense slag that was created over the weld surface will be removed. These electrodes are preferred by less-skilled operators and consequently are used for a wide variety of maintenance operations. The rutile type which is made for using with alternating current has a very stable arc, and, with its low penetrating character, is especially suitable for sheet metal joining. Another type of rutile electrodes include a comparative amount of iron powder, which oxidies and adds to the weld metal.
Lime Type Electrodes:
are generally called basic type electrodes because they produce a basic slag formed largely from limestone and fluorspar.
Decomposition of calcium carbonate forms carbon dioxide and carbon monoxide that shield the arc from atmospheric contamination. During manufacture with alkaline liquid silicates as binders, lime type electrodes are baked at much higher temperatures than those containing cellulose and thus produce welds characterized by low hydrogen contents. Such electrodes frequently are referred to as low-hydrogen electrodes, allowing them to be used on low-alloy steels where hydrogen cracking can be a problem. They are suitable for use on direct current with the electrode connected to the positive terminal.
Unskilled operators may find it more difficult to maintain a steady arc with these electrodes; thus variations with up to 8% titania (lime&#;titania electrodes) have been developed to improve arc stability. With the addition of potassium silicate as the binder, this type of electrode can be used with alternating current.
Basic electrodes are usable in all positions, although their slags are somewhat more difficult to remove; the addition of titania and sometimes zirconia makes the slags more friable when cold and thus more readily removed.
As with the cellulosic types, iron powder additions have improved the ease of operation and provide additional weld metal, and are now the most popular of the low-hydrogen types. They are used not only for carbon steels, but also for stainless steels, low-alloy steels, and even some nonferrous alloy electrodes.
Acid Electrodes:
have large amounts of iron oxides in the coating which would result in high oxygen content in the weld metal and poor mechanical properties. It is therefore necessary to incorporate large amounts of de-oxidants such as Ferro-manganese and Ferro-silicon in the flux. Although they produce smooth flat weld beads of good appearance and can be used on rusty and scaled steel items the mechanical properties tend to be inferior to the rutile and basic coated electrodes. They are also more sensitive to solidification cracking and are therefore little used.
Electrode Coatings with Very High Amounts of Iron Powder:
in which the thick coatings comprise as much as 50% of the electrode weight, are also available. The iron powder adds considerably to the amount of weld metal produced by the metallic core; thus these electrodes sometimes are referred to as high-efficiency electrodes. The relatively thick covering and the conductivity provided by the iron powder allow the electrode to rest on the weld seam to produce a flat groove weld. This sometimes is referred to as gravity welding.
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