1020 304

Effects of flux on the characteristics of plasma arc weldment

of 1020 carbon steel and 304 stainless steel

1020 304

Effects of flux on the characteristics of plasma arc weldment

of 1020 carbon steel and 304 stainless steel

Student: Sheang-Wen Shyu

Advisor: Chang-Pin Chou

A Thesis

Submitted to Institute of Mechanical Engineering College of Engineering

National Chiao Tung University in Partial Fulfillment of the Requirements

for the Degree of Doctor of Philosophy

in Mechanical Engineering

January 2009 Hsinchu, Taiwan, Republic of China

I

1020 304

AISI 1020 AISI 304

Bead-on-plate

MoO3MnO2TiO2SiO2Cr2O3Fe2O3 ZnO NiCO3

MgCO3MnCO3

EDS

II

SiO2 304

200 SiO2 60%+ MnO2 40%,

300

III

Effects of flux on the characteristics of plasma arc weldment of 1020 carbon

steel and 304 stainless steel

Student: Sheang-Wen Shyu Advisor:Chang-Pin Chou

Department of Mechanical Engineering

National Chiao Tung University

ABSTRACT

The purpose of this paper was to investigate the effects of activating flux on

the characteristics of plasma arc welding process. This study compares plasma

arc welding with TIG welding on the various properties of weldment, and also

explores the mechanism of how activating flux improves weld penetration. In

order to evaluate the effect of activating flux on the different materials, AISI

1020 low carbon steel and AISI 304 austenitic stainless steel were used to

produce a bead-on-plate welded joint. The activating fluxes were oxides (MoO3,

MnO2, TiO2, SiO2, CrO3, Fe2O3 and ZnO) and carbonates (NiCO3,MgCO3 and

MnCO3) powders. During welding, a CCD camera system was used to observe

and record images of the arc profiles.

The microstructure and morphology of the welds obtained were examined

by means of an optical microscope using transverse weld cross-sections

prepared by cutting. The retained ferrite content of welds was measured by

using the Ferritscope. Transverse tensile and Vickers hardness tests were used to

determine on the mechanical properties of weldments. EDS were employed for

studying the elemental analysis of the welds. The mean vertical displacement

method was utilized for calculating the welding angular distortion.

The experimental results indicate that higher penetration depth and

narrower HAZ range are the results of the increased energy density of the

welding heat source, and therefore the angular distortion of carbon steel and

austenitic stainless steel weldments can be reduced, while using a certain oxide

IV

flux. Physically constricting the plasma column and reducing the anode spot are

the possible mechanisms for the main contribution to the augmented weld

penetration capability. The number of ferrite in stainless steel welds was

increased due to the flux additions, and thus helps reduce hot cracking

susceptibility in welded structures. The penetration capability up to 200% can be

obtained in plasma welds that use SiO2 flux when compared with the non-flux

addition welds. The SiO2 60%+ MnO2 40% mixture flux can greatly increase

penetration depth up to around 300%. TIG and plasma welding with activating

flux could bring about large benefits in terms of productivity and cost-effect and

achieve practical use.

V

VI

1.1 -------------------------------------------------------- 1

1.2 ----------------------------------------------------------------- 3

1.3 ----------------------------------------------------------------- 4

2.1 ----------------------------------------------------- 5

2.2 ---------------------- 6

2.3 --------------------------------------------------------------- 10

2.3.1 AISI 1020 ------------------------------------ 10

2.3.2 AISI 1020 ---------------------------------------------- 12

2.3.3 AISI 1020 ---------------------------------------------- 14

2.4 ------------------------------------------------------------------- 15

2.4.1 -------------------------------------- 15

2.4.2 ----------------------------------------------------- 16

2.4.3 ----------------------------------- 19

2.4.4 ----------------------- 22

2.4.5 -------------------------------------- 24

2.5 --------------------------------------------------------------- 25

VII

2.5.1 ------------------------------------------------- 25

2.5.2 ------------------------------------------------- 25

2.5.3 ------------------------------------------------- 27

2.6 --------------------------------------------------------------- 30

2.6.1 ------------------------------------------------- 30

2.6.2 ------------------------------------------- 32

2.7 ------------------------------------------------------------------- 33

2.7.1 ----------------------------------------------------- 33

2.7.2 ----------------------------------------------------- 34

2.7.3 -------------------------- 36

2.8 ------------------------------------------ 39

2.8.1 ----------------------- 40

2.8.2 ----------------------------------------------------------- 41

2.8.3 -------------------------------------- 42

3.1 ---------------------------------------------------------------- 45

3.2 ------------------------------------------------------- 46

3.3 ------------------------------------------------------------ 46

3.4 ------------------------------------------ 48

VIII

3.5 ------------------------------------------------------------- 50

3.6 ------------------------------------------------- 52

3.7 ---------------------------------------------------------------- 52

3.8 ------------------------------------------------------- 52

3.9 ------------------------------------------------------- 54

3.10 -------------------------------------------------------- 54

3.11 -------------------------------------------------------------- 54

3.12 SEM EDS --------------------------------------------------- 55

4.1 AISI 1020 --------------------------------------------------- 56

4.1.1 ----------- 56

4.1.2 -------- 60

4.1.3 ----------- 62

4.1.4 -------------- 64

4.1.5 EDS ---------------------------------------------------- 65

4.2 304 -------------------------------------------------------- 66

4.2.1 PAW ------------ 68

4.2.2 PAW ---------------------- 71

4.2.3 ---------------------------- 72

IX

4.2.4 ------------------- 73

4.2.5 ---------------------------- 75

4.3 TIG PAW ------------------------------------------ 77

4.3.1 -------------------------------------- 77

4.3.2 -------------------------------------- 78

4.4 -------------------------------- 79

4.5 ----------------------- 84

4.5.1 ----- 84

4.5.2 ---------------------------------------------------- 87

4.5.3 EDS ---------------------------------------------------- 89

-------------------------------------------------------- 92

------------------------------------------------------------- 95

X

2-1 --------------------------------------------------- 6

2-2 (keyhole) ---------------------------- 6

2-3 PAW ---------------------------------- 7

2-4 TIG PAW ------------------------------ 8

2-5 TIG -------------------------- 9

2-6 AISI 1020 -------------------------------- 13

2-7 (a)(b)(c)(7500) ----------------- 14

2-8 -------------------------------------- 15

2-9 Fe-Cr-Ni ---------------------------------------- 20

2-10 ------------------------------------- 22

2-11 ---------------------------------------------- 26

2-12 ------------------------------- 29

2-13 ---------------------------------------------- 31

2-14 ------------------------------------- 32

2-15 ------------------------------------- 41

3-1 -------------------------------------------------- 46

3-2 (pwh/m-4a welding torch) ---------- 47

XI

3-3 (TIG) ---------------------------------------- 48

3-4 -------------------------------------------- 49

3-5 ----------------------------------------------- 51

3-6 ----------------------------------------------- 53

3-7 ----------------------------------------------------- 55

4-1 ----------- 57

4-2

---------------------------------------------------------------------- 61

4-3 -------------------- 63

4-4 ------------ 64

4-5

---------------------------------------------------------------------------- 64

4-6 PAW-Flux EDS ---------------------- 65

4-7 304

-------------------------------------------------------------------- 67

4-8 304

---------------------------------------------------------------------- 68

4-9 ----------------------------------- 70

4-10 ------------------------------- 71

4-11 ------------------------------- 72

XII

4-12 ------------------------------------- 73

4-13 ---------------------------------- 75

4-14 ---------------------------------- 76

4-15 SiO2 ----------------------- 77

4-16 SiO2 304 ------------ 78

4-17 TIG PAW

----------------------------------------------- 79

4-18 TIG

----------------------------------------------------------------- 80

4-19 PAW

-------------------------------------------------------------------------- 84

4-20 -------- 85

4-21 ----- 86

4-22 304 --------------------- 88

4-23 SEM ----------------------------------- 89

4-24 304 PAW-Flux EDS --- 90

XIII

2-1 AISI 1020 ----------------------------------------------- 11

2-2 AISI 1020 -------------------------------- 12

2-3 ---------------------------------------------- 17

2-4 -------------------------------------------------- 17

2-5 -------------------------------------------------- 18

2-6 ----------------------------------------------------- 26

2-7 -------------------------------------------- 27

4-1 PAW-Flux EDS ---------------------- 66

4-2 -------------------------------- 77

4-3 304 -------- 86

4-4 304 PAW-Flux ----------------- 87

4-5 304 PAW-Flux EDS ------- 91

1

1.1

plasma arc welding, PAW

2

metal spraying

PVDCVD[1]

PAW

PAW

PAW MIG MIG TIG)

PAW TIG

PAW

PAW

(Activating

3

flux)

TIG

PAW

PAW

1.2

PAW

AISI 1020 304 PAW

AISI 1020 AISI 304

PAW

AISI 1020 AISI 304

PAW

AISI 1020 AISI 304

PAW

4

AISI 1020 AISI 304

PAW

AISI 1020 AISI 304

PAW

1.3

Bead-on-plate AISI

1020 AISI 304

EDS

5

2.1

( 2-1)

( 2-2)

(cutting)metal spraying[1-4]

6

2-1 [1]

2-2 (keyhole)[1]

2.2 [3-5]

7

TIG

TIG (

2-3 )( Insert

tip)(

)( 0.8

5.0mm)

(

)

(a)TIG (b)MIG

(c)PAW 2-3 PAW [1]

8

MIG TIG

TIG

( 2-4 )

2-4 TIG PAW [5]

2-5 TIG

TIG 15 KW/cm2

50100 KW/cm2

9

2-5 TIG [5]

TIG

TIG 10A

1A 20 mA

TIG

1.

10

2.

3.

4.

5.

6.

7.

TIG :

1. 25

2.

3.

2.3

2.3.1 AISI 1020 [6]

AISI(American Iron and Steel Institute) SAE(Society of Automotive

Engineers) 4 5

3 AISI 1020

0.20 2-1 2-2

11

0.12~0.20%

P S 0.12~0.050%

2-1 AISI 1020 [6]

AISI 1020 1500~1600 F

2300~1800 F.

900~1200 F.

1020

1600 to 1800 F

600 -1000 F

AISI 1020

12

2-2 AISI 1020 [6]

6.7

(Btu/lb/Deg F - [32-212 Deg F]) 0.107

7.86

(lb / cu. in.) 0.284

(F) 2760

Poissons Ratio 0.3

Btuin/ft2h 360

ksi 60

ksi 33

B76

137

C0.18-0.23 Mn0.30~0.60

P0.04S0.05

2.3.2 AISI 1020

2-6 Fe3C

2.11%

13

A3

Acm A1

A1

2-7 (

)

C

2-6 AISI 1020 [6]

14

2-7 (a)(b)(c)(7500)

2.3.3 AISI 1020

A1

(heat-affected zone)

CCT

2-8

A1

A1

15

2-8 (a)(b)

(c)[7]

2.4

2.4.1 [8]

(Cr) Cr

Cr Cr2O3

Cr 12% 30%Cr

12%Cr

12%Cr

13 12%(corrosion resisting steel)

16

30%

(Ni)

(Ni - Cr)

2.4.2 :

:

l.(matensitic stainless steels)

2.(austenitic stainless steels)

3.(ferritic stainless steels)

4.(precipitation stainless steels)

( 2-3 2-4 ) [8]

(AISI)

( 2-5) 304

17

2-3 [8]

1.

(AISI 400 )

1.

2.

2.

(AISI 200 300 )

3.

4.

2-4 [8]

g/cc

Cu=1

cal/g

%

m/cm

7.9 1395 0.12 9.6 0.117 3.0 75.0

7.7 1430 0.17 9.5 0.118 3.0 57.0

7.7 1507 0.17 9.5 0.334 3.0 60.0

18

2-5 [8]

2xx Cr-Ni-Mn

3xx Cr-Ni

4xx Cr

4xxc

0.12

Cr

5xx Cr-Mo

PH (

)

+

Cr-Ni (

)

Fe-Cr-Ni

16%

19

C 0.2%Cr l7-20%Ni

7-10% 18-8

(face-centered cubic , FCC)

(preheat treatment)(post-weld heat treatment)[9]

2.4.3

(ferrite structure)

(cooling rate)[10]

Fe-Cr-Ni (pseudo-binary diagram)

2-9

(++L) LL++

(primary ferrite)

20

(retained

delta-ferrite)

L+L

(primary austenite)

Liquid

+L++L

+L

-Solvus+ -Solvus

%Cr %NiCr / Ni

Tem

pera

ture

Low Ferrite

High Ferrite

FullyAustenitic

2-9 Fe-Cr-Ni [11]

Suutala [12-17]

Brooks [18,19]Katayama [20] Savage [21]

21

Suutala

Creq / Nieq 2-10

1.A ( ab )Creq / Nieq 1.48

vermicular

ferrite

2.B ( cd )1.48 Cr eq / Nieq 1.95

vermicular ferrite lathy ferrite

3.C ( e )Creq / Nieq 1.95

lathy ferrite

(widmanstatten)

(habit plane)

22

2-10 [12]

2.4.4

[22-26]

23

1.

(hot cracking)

2. SPSi

2~8%

3.500~800

Fe Cr

4.

5.

24

6.

(pitting)

(stress corrosion

cracking)(sensitization)

7.

2.4.5

1.5 1/3

(1)(2)

(3)

[27]

(1)

25

(2)

(thermal history)

(3)

2.5

2.5.1

1.

2.(

)

2.5.2 [28-29]

:

26

1.(density)

2-6

(CO2>Ar>O2>N2>He>H2)

2-6 [29]

Welding gas Ar He CO2 O2 H2 N2

Specific

gravity

1.380 0.137 1.530 1.105 0.069 0.967

2.(thermal conductivity)

[30] 2-11

2-11 [30]

27

3.(ionization potential)

2-7

(He>Ar H2 N2>CO2>O2)

2-7 [29]

Welding gas Ar He CO2 O2 H2 N2

Ionization

potential b

15.7 24.5 14.4 12.5 15.6 15.5

b Unit is electron volts

2.5.3 [29]

1.(argon)

(1).

(2)

28

(3)

(4)()

(5)()

(6)()

2.(helium)

(1)

(2)()

(3)()

(4)()

(5)()

(6)()

(7)

3.(carbon dioxide)

(1)()

(2)

(3)

(4)

(5)

29

4.(nitrogen)

(1)()

(2)

(3)

(4)

(5)

( 2-12(a))

( 2-12(a)

) -( 2-12(b))

Ar He Ar-He

(a) (b)-

2-12 [9]

30

2.6

2.6.1

2-13

1.(transverse shrinkage)

2.(longitudinal shrinkage)

3.(angular distortion)

4.(rotational distortion)

5.(bending distortion)

6.(buckling distortion)

31

(A) Transverse Shrinkage (B) Longitudinal Shrinkage

(C) Angular Distortion (D) Rotational Distortion

(E) Bending Distortion (F) Buckling Distortion

2-13[33]

32

2.6.2 [31-34]

(butt-welded)

2-14

(transverse shrinkage force)

( 2-14 A )

( 2-14 B )

ACentroid of the filler metal

BCentroid of the base metal

FTransverse shrinkage force

2-14 [34]

33

2.7

2.7.1 [1]

()

(1)

COCO2

H2H2O

(2)

AlTiSiMnC

(3)

34

(4)

CaCO3K2CO3

Na2CO3KNO3 KNaCa

2.7.2 [1]

1.(E6011TC-11)

30

2.(E6013TR-13R-13)

35

35

3.(D4303F-03TAC-03)

30 20

4.(D4301E-10EL-10)

30

5.(E7016D4316)

CO2

(dilution)

36

6.(E7018E7028)

25~40

7.(E7024T-24)

50

170~200

T

8.(E-6027T-27T-27L)

2.7.3

(International

Institute of Welding, IIW)(basic index B.I.)

37

B.I.[35-36]

)ZrO+TiO+OAl(21

+SiO

)FeO+MnO(21

+CaF+OK+ONa+BaO+MgO+CaO=.I.B

22322

222

1.( B.I.1.5)

B.I. Mn P S

B.I.B.I.

(Af)

38

( Af0.6 )( Af=0.3~0.6 )( Af=0.1~0.3 )

( Af0.1 )

(weld pool)

304

[37-38]

1. SiO2Cr2O3ZnOMnO2Fe2O3 TiO2

1

2.

ZnOSiO2 TiO2

3. Al2O3 304

4. 304 SiO2Cr2O3ZnOMnO2

Fe2O3 TiO2

100A 150A 2

39

200A 3

5. CaF2NaF

CaF2

6.

SiO2 Na2CO3

SiO2

7. SiO2Cr2O3ZnOMnO2Fe2O3 TiO2 150A

200A 100A

2.8

304 HAZ

[39-42]

[43]

SMgAlCa

[44-49][50-54]

40

2.8.1

(weld pool)

(1)(2)(3)

(4)

2-15

(dr/dt) 2-15(a)

SO

(dr/dt) 2-15(b)

()(

)

SO

41

Weld pool

Tungstenelectrode

Arc

Weld pool

Tungstenelectrode

Arc

Weld pool

Tungstenelectrode

Arc

Weld pool

Tungstenelectrode

Arc

dr/dt0

Aerodynamicdrag force

(d)Buoyancy(c)Electromagnetic(or Lorentz)

(b)Thermocapillary force(a)Aerodynamic drag force

2-15 [51]

2.8.2 [50-54]

(anode root)

80

42

2.8.3 [55-57]

1.(S)

S ,/(D/W)

S S

50ppm

D/W S 50ppm

D/W S

(ripple)(undercut) S

2.(O)

O D/W O 60ppm D/W

0.3 O 100ppm D/W 0.7

O 60ppm

3.(Al)

43

Al 40ppmD/W 0.7Al 90ppm

D/W 0.3 Al Al O

O Al D/W

Al Al

4.(Si)

Si 0.5 D/W Si Si

0.5D/W Si Si

Si

O D/W

5.(Mn)

Mn 1.0D/W Mn

Mn Mn

O D/W

6.

Ar O2 SO2 O2

44

Ar 5H2

45

3.1

TIG-flux PAW-flux

46

3.2

AISI 304 AISI 1020

(constraint-free)

#400

150mm150mm5mm 3-1

3-1

3.3

PAW

TIG 3-23-3

47

bead-on-plate

3mm AISI 1020 AISI 304

1501505mm 75A100A

125A 100mm/min125 mm/min150 mm/min

3-2 pwh/m-4a welding torch

48

3-3 TIG

3.4

Cr2O3Fe2O3MnO2MoO3SiO2

TiO2 ZnO

Cr2O3SiO2 TiO2 MnO2MoO3

NiCO3MgCO3MnCO3 #400

10mm 150mm

3-4

49

(c) Mixing

0.000

PowderA

PowderB

(a) Weighing (b) Grinding

(d) Coating

150mm

150mm

10mm

Brush

Flux

Base metal

Acetone

Fluxpowder

3-4

50

3.5

3-5 P1P2 P3

0.005mm 3-5

0.01mm

P1P2 P3

(A~E)(F~J) Z 5

X 50mm Z(50

tan 1- Z= )

3-5 5

51

Start point of measureEnd point of measureReference point of measure

A

B

C

D

E

F

G

H

I

J

P1

P3

P2

30 mm

15 mm

Y

X

Z

X

Direction of measure

X

Z

(b) Measuring position (c) Measuring theory

Flux

Directi

on of tra

vel

Torch

Scribing Locating

Drilling Leveling

Welding Measuring

Specim

en

Indicator

Welds

Indicator

(a) Measuring step

3-5

52

3.6

TIG&PAW-Flux

3-2

3.7

1020 304

#1200

0.3m

(optical microscope)

Olympus BX60M

AISI 304 10g CuSO4+50ml HCl+50ml H2O AISI 1020

2mlHNO3100mlC2H5OH 4~5

3.8

40mm

Marbles (10g CuSO4+50ml

53

HCl+50ml H2O)AISI 304 Nital2AISI 1020

4~5 (stereomicroscope)

(Depth)(Width)(Depth

Width Ratio) 3-6

WDTR

DT

W

(a)

R

D T

W

(b)

R

D T

W

(c)R

3-6 (a) (b)(c)(WDTR

54

3.9

Ferritscope M10B-FE

1.2mm 0.04FN

3.10

Matsuzawa MHT-1

200 15

1mm 0.25mm

3.11

ASTM E8 3-7

10KN Instron 8501

0.05mm/sec(UTS)

55

(YS)(elongation)

32 3230

1006.25 3R

3.5

10

Unit : mm

3-7

3.12 SEM EDS

1020 304

(energy dispersive spectrometer, EDS)

(scanning electron microscope, SEM)

SEM JEOL JSM 6360 EDS

OXFORD INCA Energy 300 B~ U

5~92

56

4.1 AISI 1020

4.1.1

4.1

MoO3MnO2

TiO2SiO2 Cr2O3 AISI 1020

MoO3

(125A100mm/min)

33%

(75A150mm/min) MoO3

21%

57

With MoO3 Flux 75A 100A 125A

100

mm/min

125

mm/min

150

mm/min

With MnO2 Flux 75A 100A 125A

100

mm/min

125

mm/min

150

mm/min

4-1

58

With TiO2 Flux 75A 100A 125A

100

mm/min

125

mm/min

150

mm/min

With SiO2 Flux 75A 100A 125A

100

mm/min

125

mm/min

150

mm/min

4-1

59

With Cr2O3 Flux 75A 100A 125A

100

mm/min

125

mm/min

150

mm/min

Without Flux 75A 100A 125A

100

mm/min

125

mm/min

150

mm/min

4-1

60

4.1.2

4-2

MoO3

MnO2TiO2SiO2 Cr2O3

28%

12%

61

100 125 150Travel Speed (mm/min)

0.0

0.2

0.4

0.6

0.0

0.2

0.4

0.6

Without Flux

With Cr2O3 Flux

0.0

0.2

0.4

0.6

With SiO2 Flux

0.0

0.2

0.4

0.6

With TiO2 Flux

0.0

0.2

0.4

0.6

With MnO2 Flux

0.0

0.2

0.4

0.6

With MoO3 Flux

Dep

th /

Wid

th R

atio

75A 100A 125AWelding Current

4-2

62

4.1.3

4-3

MoO3MnO2

TiO2SiO2 Cr2O3

9%

8%

63

100 125 150Travel Speed (mm/min)

160

180

200

220

240

160

180

200

220

240

Without Flux

With Cr2O3 Flux

160

180

200

220

240With SiO2 Flux

160

180

200

220

240With TiO2 Flux

160

180

200

220

240With MnO2 Flux

160

180

200

220

240With MoO3 Flux

Vic

kers

Har

dnes

s (H

v)75A 100A 125A

Welding Current

4-3

64

4.1.4

4-4 4-5

NiCO3

Flux Without flux NiCO3 MgCO3 MnCO3

Welding current 125A

Travelling speed 150mm/min

4-4

Welding current 125ATravelling speed 150mm/min

0

0.05

0.1

0.15

0.2

0.25

0.3

0.35

0.4

0.45

Without flux NiCO3 MgCO3 MnCO3

Dep

th/W

idth

Rat

io

Without flux NiCO3 MgCO3 MnCO3

4-5

65

4.1.5 EDS

EDS 4-6 4-1

4-6 NiCO3

4-1

NiCO3

Without flux

NiCO3

4-6 PAW-Flux EDS

66

4.1 PAW-Flux EDS

Without flux NiCO3 flux

Element Weight, % Atomic, Element Weight, % Atomic,

C 4.57 18.20 C 7.41 26.98

Ti 0.24 0.24 P

S S 0.02 0.02

Cr 0.22 0.20 Cr

Mn 0.37 0.32 Mn 1.59 1.27

Fe 94.83 80.78 Fe 90.18 70.62

Co 0.22 0.18 Co 0.17 0.13

Ni 0.10 0.08 Ni

Si Si 0.63 0.99

4.2 304

4-7 MoO3 MnO2 T iO2 SiO2Cr2O3Fe2O3 ZnO

4-74-8 SiO2 304

200

350

67

Without Flux MoO3 Flux MnO2 Flux

TiO2 Flux SiO2 Flux Cr2O3 Flux

Fe2O3 Flux ZnO Flux

Welding current 125A

Travelling speed 150mm/min

4-7 304

68

00.20.40.60.8

11.2

With

out fl

uxMo

O 3Mn

O 2 TiO2

SiO2

Cr 2O 3

Fe 2O 3 Zn

O

Welding current 125ATravelling speed 150mm/min

Dep

th/W

idth

Rat

io

4-8 304

4.2.1 PAW

4-9

125 min MoO3MnO2

SiO2 Cr2O3Fe2O3 ZnO 125A

2-14

69

4-9 MoO3MnO2SiO2 Cr2O3

Fe2O3Cr2O3 TiO2 75A

(MnO2=2.18, TiO2=2.02, Fe2O3=2.1, MoO3=2.28, mm)

Pavlovsky [58]

Watanabe [58]

0.5

0.5

0.5

75A MnO2TiO2Cr2O3Fe2O3

SiO2

2-14

70

/ 0.5

4-9

75A

4-9

0

0.5

1

1.5

2

2.5

0 50 100 150

Welding Current(A)

Angula

r D

isto

ration(d

egre

e)

without fluxMoO3 MnO2 TiO2 SiO2 Cr2O3 Fe2O3 ZnO

Without flux MoO3 MnO2 TiO2 SiO2 Cr2O3 Fe2O3 ZnO

71

4.2.2 PAW

SiO2 304

SiO2

4-10 SiO2

SiO2,

0

10

20

30

40Without Flux

75A100A125A

75 100 125 150 175Travel Speed (mm/min)

0

10

20

30

40SiO2 Flux

75A100A125A

Wel

d Ar

ea (m

m2 )

4-10

72

4.2.3

4-11 4-12

SiO2

SiO2

0

2

4

6

8

10Without Flux

75A100A125A

75 100 125 150 175Travel Speed (mm/min)

0

2

4

6

8

10SiO2 Flux

75A100A125A

Pen

etra

tion

(mm

)

4-11

73

Without

Flux 75 A 100 A 125 A

100

mm/min

125

mm/min

150

mm/min

(a)

SiO2 Flux 75 A 100 A 125 A

100

mm/min

125

mm/min

150

mm/min

(b) SiO2

4-12

4.2.4

[60-61] 4-13

74

SiO2

[20-25] SPSi

(pitting)

75

2

4

6

8

10

12

Without Flux 75A100A125A

75 100 125 150 175Travel Speed (mm/min)

2

4

6

8

10

12

SiO2 Flux 75A100A125A

Ferr

ite C

onte

nt (F

N)

4-13

4.2.5

SiO2

4-14

5

SiO2

76

75 100 125 150 175Travel Speed (mm/min)

140

160

180

200SiO2 Flux

75A100A125A

140

160

180

200

Without Flux 75A100A125A

Vic

kers

Har

dnes

s (H

V)

SiO2Flux

Without Flux

4-14

4.2 304

125A 125mm/min SiO2

77

4.2

FFlluuxx UTS(MPa) Elongation(%)

Without flux 589.52 32.53

SiO2 flux 612.24 31.27

4.3 TIG PAW

4.3.1

(a) TIG weld (b) PAW weld

4-15 SiO2

4-15 304 TIG PAW

4-15 (a) SiO2

4-15 (b)

PAW

78

4.3.2

4-16 TIG PAW

125A SiO2

PAW TIG

TIG

4-18. 4-20.

4-17

Without flux SiO2 flux

TIG weld

PAW weld

4-16 SiO2 304

79

50 75 100 125 150Welding Current (A)

1

2

3

4

5

6Pe

netra

tion

(mm

)

PAWTIG

With flux

Without flux

Travelling Speed : 150 mm/minFlux SiO2

4.4

ATIG

TIG CCD

4-18 SiO2

TIG

(

) 4-18

4-17. TIG PAW

80

TIG Without flux SiO2 flux

Plasma column

Anode spot

4-18 304 TIG

(1)

Heiple [45-49,63,64]

(ddT)

81

(outward flow) 2-15(a)

(inward flow)

2-15(b)

(2)

4-18

82

(anode spot)

/

[47,48]

(aerodynamic drag force)

BPAW

TIG

83

TIG

D.S. Howse W. Lucas

65

4-19

PAW TIG

1)2)

84

PAW Without flux SiO2 flux

Plasma column

Anode spot

4-19. PAW

4.5

4.5.1

SiO2TiO2 Cr2O3MoO3 Fe2O3 ZnO

MnO2 125A 125 min 4-20

60%MnO2

250%

4-20 4-21 4-3 40%~80%MnO2 20%~60% SiO2

85

95% 60% SiO2-40% MnO2

SiO2 MnO2

[60-61]

Flux MnO2 80%

Other 20% MnO2 60%

Other 40%

MnO2 40%

Other 60%

MnO2 20%

Other 80%

SiO2

TiO2

Cr2O3

MOO3

Fe2O3

ZnO

Welding current 125A Travelling speed 125mm/min

4-20

86

4-21

4-3 304

Flux MnO2 80%

Other 20% MnO2 60%

Other 40%

MnO2 40%

Other 60%

MnO2 20%

Other 80%

SiO2 0.97 0.98 0.92 0.77

TiO2 0.82 0.77 0.89 0.97

Cr2O3 0.55 0.76 0.8 0.84

MOO3 0.81 0.9 0.88 0.87

Fe2O3 0.77 0.65 0.63 0.55

ZnO 0.81 0.97 0.92 0.88

Welding current 125A Travelling speed 125mm/min

0

0.2

0.4

0.6

0.8

1

1.2

SiO2 TiO2 Cr2O3 MoO3 Fe2O3 ZnO

Dep

th/W

idth

Rat

io

20%

40%

60%

80%

MnO2

SiO2 TiO2 Cr2O3 MoO3 Fe2O3

Dep

th/W

idth

Rat

io

87

4.5.2

4-4 60%SiO2-40%MnO2 304

SiO2 MnO2

4-22

60%SiO2-40%MnO2

4-23 60%SiO2 -40%MnO2 flux

SEM PAW

Dimple

4-4 304 PAW-Flux

FFlluuxx UTS(MPa) Hardness (Hv)

Without flux 589.52 169.5

With flux

(60%SiO2-40%MnO2)

620.32 178.3

88

Without flux 60%SiO2 -40%MnO2 flux

200x 200x

200x 200x

4-22. 304

89

Without flux 60%SiO2 -40%MnO2 flux

4-23 SEM

4.5.3 EDS

EDS 4-5

4-24 SiO2 MnO2

90

Without flux

60%SiO2 -40%MnO2 flux

4-24 304 PAW-Flux EDS

91

4-5 304 PAW-Flux EDS

Without flux 60%SiO2 -40%MnO2 flux

Element Weight, % Atomic, % Element Weight, % Atomic, %

Cr 20.08 21.17 Cr 20.97 22.12

Mn 1.17 1.16 Mn 0.69 0.69

Fe 71.10 69.79 Fe 70.84 69.56

Ni 6.93 6.47 Ni 6.88 6.43

Si 0.72 1.41 Si 0.62 1.20

92

AISI 1020 AISI 304

304

304

A. AISI 1020

1. MoO3MnO2TiO2SiO2 Cr2O3

MoO3 33%

2.

9

3. NiCO3 MgCO3MnCO3

4.

B. AISI 304

1.

93

2. SiO2

3.

SiO2

4. TIG

5. SiO2

6. MoO3MnO2SiO2 Cr2O3Fe2O3 ZnO

125A

7. - SiO2 304

200

8. SiO2 60%+ MnO2 40%,

300

94

9. SiO2 60%+ MnO2 40%

- 95 -

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1997

2.

19975pp.44~48

3.

19977p.50

4. 19939

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5. 75 1

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9.

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