Defects/imperfections in welds - slag inclusions

Prevention of slag inclusions by grinding between runs

The characteristic features and principal causes of slag imperfections are described.

Identification
Fig. 1. Radiograph of a butt weld showing two slag lines in the weld root Slag is normally seen as elongated lines either continuous or discontinuous along the length of the weld. This is readily identified in a radiograph, Fig 1. Slag inclusions are usually associated with the flux processes, ie MMA, FCA and submerged arc, but they can also occur in MI welding.

Causes
As slag is the residue of the flux coating, it is principally a deoxidation product from the reaction between the flux, air and surface oxide. The slag becomes trapped in the weld when two ad!acent weld beads are deposited with inade"uate o#erlap and a #oid is formed. $hen the next layer is deposited, the entrapped slag is not melted out. Slag may also become entrapped in ca#ities in multi%pass welds through excessi#e undercut in the weld toe or the une#en surface profile of the preceding weld runs, Fig 2. As they both ha#e an effect on the ease of slag remo#al, the ris& of slag imperfections is influenced by

Type of flux

$elder techni"ue

The type and configuration of the !oint, welding position and access restrictions all ha#e an influence on the ris& of slag imperfections. Fig. 2. The influence of welder technique on the risk of slag inclusions when welding with a basic MM !"#1$% electrode

a% Poor !conve&% weld bead profile resulted in pockets of slag being trapped between the weld runs

b% '(ooth weld bead profile allows the slag to be readily re(oved between runs

Type of flux
'ne of the main functions of the flux coating in welding is to produce a slag which will flow freely o#er the surface of the weld pool to protect it from oxidation. As the slag affects the handling characteristics of the MMA electrode, its surface tension and free(ing rate can be e"ually important properties. For welding in the flat and hori(ontal)#ertical positions, a relati#ely #iscous slag is preferred as it will produce a smooth weld bead profile, is less li&ely to be trapped and, on solidifying, is normally more easily remo#ed. For #ertical welding, the slag must be more fluid to flow out to the weld pool surface but ha#e a higher surface tension to pro#ide support to the weld pool and be fast free(ing. The composition of the flux coating also plays an important role in the ris& of slag inclusions through its effect on the weld bead shape and the ease with which the slag can be remo#ed. A weld pool with low oxygen content will ha#e a high surface tension producing a con#ex weld bead with poor parent metal wetting. Thus, an oxidising flux, containing for example iron oxide, produces a low surface tension weld pool with a more conca#e weld bead profile, and promotes wetting into the parent metal. *igh silicate flux

produces a glass%li&e slag, often self detaching. Fluxes with a lime content produce an adherent slag which is difficult to remo#e. The ease of slag remo#al for the principal flux types are+

,utile or acid fluxes % large amounts of titanium oxide -rutile. with some silicates. The oxygen le#el of the weld pool is high enough to gi#e flat or slightly con#ex weld bead. The fluidity of the slag is determined by the calcium fluoride content. Fluoride% free coatings designed for welding in the flat position produce smooth bead profiles and an easily remo#ed slag. The more fluid fluoride slag designed for positional welding is less easily remo#ed. /asic fluxes % the high proportion of calcium carbonate -limestone. and calcium fluoride -fluospar. in the flux reduces the oxygen content of the weld pool and therefore its surface tension. The slag is more fluid than that produced with the rutile coating. Fast free(ing also assists welding in the #ertical and o#erhead positions but the slag coating is more difficult to remo#e.

Conse"uently, the ris& of slag inclusions is significantly greater with basic fluxes due to the inherent con#ex weld bead profile and the difficulty in remo#ing the slag from the weld toes especially in multi%pass welds.

Welder technique
$elding techni"ue has an important role to play in pre#enting slag inclusions. 0lectrode manipulation should ensure ade"uate shape and degree of o#erlap of the weld beads to a#oid forming poc&ets which can trap the slag. Thus, the correct si(e of electrode for the !oint preparation, the correct angle to the wor&piece for good penetration and a smooth weld bead profile are all essential to pre#ent slag entrainment. In multi%pass #ertical welding, especially with basic electrodes, care must be ta&en to fuse out any remaining minor slag poc&ets and minimise undercut. $hen using a wea#e, a slight dwell at the extreme edges of the wea#e will assist sidewall fusion and produce a flatter weld bead profile. Too high a current together with a high welding speed will also cause sidewall undercutting which ma&es slag remo#al difficult. It is crucial to remo#e all slag before depositing the next run. This can be done between runs by grinding, light chipping or wire brushing. Cleaning tools must be identified for different materials eg steels or stainless steels, and segregated. $hen welding with difficult electrodes, in narrow #ee butt !oints or when the slag is trapped through undercutting, it may be necessary to grind the surface of the weld between layers to ensure complete slag remo#al.

Best practice

The following techni"ues can be used to pre#ent slag inclusions+ 1se welding techni"ues to produce smooth weld beads and ade"uate inter%run fusion to a#oid forming poc&ets to trap the slag 1se the correct current and tra#el speed to a#oid undercutting the sidewall which will ma&e the slag difficult to remo#e ,emo#e slag between runs paying particular attention to remo#ing any slag trapped in cre#ices 1se grinding when welding difficult butt !oints otherwise wire brushing or light chipping may be sufficient to remo#e the slag.

Acceptance standards
Slag and flux inclusions are linear defects but because they do not ha#e sharp edges compared with crac&s, they may be permitted by specific standards and codes. The limits in steel are specified in /0 02 34567 -IS' 4567. for the three "uality le#els. 8ong slag imperfections are not permitted in both butt and fillet welds for 9uality 8e#el / -stringent. and C -moderate.. For 9uality 8e#el :, butt welds can ha#e imperfections pro#iding their si(e is less than half the nominal weld thic&ness. Short slag related imperfections are permitted in all three "uality le#els with limits placed on their si(e relati#e to the butt weld thic&ness or nominal fillet weld throat thic&ness.