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FLUXES FOR WELDING

BY
JABIN MATHEW BENJAMIN
13MY04
DEPT. OF METALLURGICAL ENGINEERING

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NEED FOR FLUXES

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Oxide Formation

Sources of O2

Oxide fluxes
Atmosphere air
Slag-metal reactions

Effects

Reduces hardenability of weld

Promotes porosity
Produces inclusions
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NEED FOR FLUXES

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Inclusion Formation.

Sources of inclusions

Mechanical entrapment of nonmetallic slag

Reactions between metallic alloy elements and nonmetallic

tramp elements
Types
Oxides
Sulfides
Nitrides
Carbides

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FLUXES
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Added to the welding environment to improve arc stability

To provide a slag and with low density

Covers the hot weld metal and protects it from the atmosphere.

To add alloying elements

The flux, by providing easily ionized atoms, plays an important

role in welding by improving arc stability.

To improve weld metal properties

Refine the weld pool (deoxidation and desulfurization)

To avoid formation to oxide and sulphide inclusions

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Types Of Fluxes
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Halide-type fluxes

CaF2NaF
CaF2BaCl2NaF,
KClNaClNa3AlF6

Halideoxide-type fluxes

CaF2CaOAl2O3
CaF2CaOSiO2
CaF2CaOMgOAl2O3.

Oxide-type fluxes

MnOSiO2
FeOMnOSiO2
CaOTiO2SiO2.

Oxygen free
Used for Al and Ti

Slightly oxidizing
High-alloy steels

Low-carbon or low alloy steels

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Basicity Index
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B.I =

B.I < 1 : ACIDIC FLUX

1 < B.I < 1.2 : NEUTRAL FLUX
B.I > 1.2 : BASIC FLUX

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Oxide Fluxes
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Basic Oxides
K2O, Na2O, CaO, MgO
Donors of free
oxide ions
Cleaner weld
Lower non metallic
inclusions
High toughness of
weld
Greater tendency
to absorb moisture
Slag detachability
not be very good

Acidic Oxides
SiO2, TiO2, P2O5

Amphoteric Oxides
Al2O3, Fe2O3, Cr2O3

Acceptors of oxide
ions
Excellent slag
behavior
Improves weld bead
morphology
High deposition rate
Moderate strength
weld
Rust proof
High welding speed

Neutral oxide

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Functions of flux components

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CaO

Strong desulfurizer

MnO

Increased penetration

SiO2

Lower content increases the width to depth ratio.

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Slag Formation
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Slag a mixture of glass and crystalline structure

Properties required

Melt below the melting temperature of base metal

Density less than base metal to reduce slag entrapment
Must possess proper viscosity in the temperature range of
1450 to 1550 C
Easily detach from the weld deposit

Function

Solidify on the weld deposit to protect the surface from

oxidation during cooling.

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Shielded Metal Arc Welding

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Electrode is covered with flux material which performs the functions.

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Flux-cored Arc Welding (FCAW)

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Uses a hollow wire filled with flux reagents and ferro-additions.

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FCAW Fluxes
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Carbon-dioxide-shielded FCAW

Titania
Lime

High CO2 content as carbonates

Self-shielded FCAW

Fluorspar-aluminum
Fluorspar-titania

Low CO2 content

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Submerged Arc Welding

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FLUXES USED:
Manganese silicate
Aluminate basic
Alumina

The flux is supplied from a hopper, which travels with the torch. No
shielding gas is needed because the molten metal is separated
from the air by the molten slag and granular flux.
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Bonded fluxes

Non metallic and ferro additions with low temperature

binders
Agglomerated fluxes
Similar to bonded but used with ceramic glass binder
cured at high temperature
Fused fluxes
Homogeneous glass mixture of proper flux mixture into
water

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Fluxes and Weld Penetration

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High viscosity
Confine the molten weld pool
Increases the heat input for a given area
Deeper penetration.
Flux composition
Affects arc stability
More ionized particles more stable arc
A more stable arc will produce deeper penetration
Surface tension
Increases weld penetration.
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Finally a welding flux must also..

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Stabilize arc and control arc resistivity

Permit use of different types of current and polarity
Promote slag detachability
Produce smooth weld contour
Reduce spatter and fume
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Reference
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Jackson, C. E., "Fluxes and Slags in Welding," W. R. C Bulletin, 190,

(1977).
Janzen, H. E "An Investigation of the SiO-MnO-CaO/CaF2 Welding
Flux System, "Thesis, Colorado School of Mines,T-1970, (1977).
ASM handbook, Vol. 6.

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THANKYOU

2/12/15