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In welding consumables with a flux the major source is the flux. Most
fluxes consist of various minerals, chemicals and alloys which are glued
together with a chemical known as Sodium or Potassium Silicate
(sometimes called WaterGlass). It is the major component of washing
powder (Daz etc).
For this reason these types of minerals are avoided when making low
hydrogen welding consumables, however, sometimes the mineral has to be
added to make the consumable work. If we had “NO HYDROGEN” consumables
they wouldn't weld very well.
Wires are drawn (a process of reducing the diameter) and this needs a
lubricant. The lubricant is known as soap and does contain soap amongst
other things. This is the main source of hydrogen in MIG wires and a
secondary source in flux cored wires. Wires that feel 'sticky' will
almost certainly evolve significant amounts of hydrogen. Otherwise MIG
wire is one of the lowest Hydrogen contributors where 1ml / 100g weld
metal is quite normal. In fluxes 3 ml / 100g weld metal is considered to
be excellent, whilst less than 5 ml is the standard lower limit.
Some steels can tolerate more hydrogen than others. In general the
softer the steel the better it can cope. It can be stretched.
Another factor is stress. All welds will be stressed but some joints are
naturally more stressed than others and some are badly designed. The
least stressed are those that can move. The greatest stresses are very
rigid joints and especially the last part of a structure. For example if
you were welding shut a manhole cover. The first side would be able to
move, the next one would be held by the first weld. And so on until to
get to the last side. This would be very rigid and contain the highest
stresses. Partial penetration joints (notches) significantly increase
these stresses and attract hydrogen so are particularly prone points.
We need all 3 factors to cause the crack. One factor can be massive
whilst the other two can be minimal. Significantly remove one of the
factors and we significantly reduce the susceptibility.
* Use soft steel. S235, S275, s355 or the old 43, 50, 55 series are
soft and highly unlikely to crack. Sometimes you need harder steel
so in these cases you need to reduce the other factors.
* Reduce the stress. Allow the joint to move and eliminate stress
raisers such as notches. Preheating reduces the stresses by reducing
the thermal shock. Higher strength steel increases rigidity and
therefore stresses.
* Allow the Hydrogen to diffuse out of the steel. Keep it warm, again
preheating will increase the time for diffusion. Allow it to cool
slowly after welding, pack it in sand.
Use low hydrogen consumables.
* Use austenitic steel consumables (Stainless E309, E312, E308Mo,
E307). These compositions have the ability to absorb the hydrogen
within the steels structure.
* Use high heat input processes or parameters.
Welding Steels
<http://www.mig-welding.co.uk/steels.htm>
Mild Steel
<http://www.mig-welding.co.uk/mild-steel.htm>
Corten
<http://www.mig-welding.co.uk/corten.htm>
Weldox
<http://www.mig-welding.co.uk/weldox.htm>
Hardox
<http://www.mig-welding.co.uk/hardox.htm>
Stainless Steel
<http://www.mig-welding.co.uk/stainless.htm>
Chrome Moly
<http://www.mig-welding.co.uk/chrome-moly.htm>
Engineering Steels
<http://www.mig-welding.co.uk/engineering-steels.htm>
Cast Iron
<http://www.mig-welding.co.uk/welding-cast-iron.htm>
<http://www.mig-welding.co.uk/cast-steel.htm>
Wrought Iron
<http://www.mig-welding.co.uk/wrought-iron.htm>
Hardfacing
<http://www.mig-welding.co.uk/hardfacing.htm>
Hydrogen Embrittlement
<http://www.mig-welding.co.uk/hydrogen-embrittlement.htm>