Effect of Flux Ratio on Droplet Transfer Behavior in Metal-Cored Arc Welding
The effect of flux ratio on metal transfer behavior during metal-cored arc welding was elucidated through investigation using a standard solid wire and three metal-cored wires with flux mass ratios of <b>(2-2)</b> 10%, 15%, and 20%. Investigation was performed using a shadowgraph techniq...
| Main Authors: | , , , , , , , , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
MDPI AG
2022-06-01
|
| Series: | Metals |
| Subjects: | |
| Online Access: | https://www.mdpi.com/2075-4701/12/7/1069 |
| _version_ | 1797433302196420608 |
|---|---|
| author | Ngoc Quang Trinh Shinichi Tashiro Tetsuo Suga Tomonori Kakizaki Kei Yamazaki Tomokazu Morimoto Hiroyuki Shimizu Ackadech Lersvanichkool Hanh Van Bui Manabu Tanaka |
| author_facet | Ngoc Quang Trinh Shinichi Tashiro Tetsuo Suga Tomonori Kakizaki Kei Yamazaki Tomokazu Morimoto Hiroyuki Shimizu Ackadech Lersvanichkool Hanh Van Bui Manabu Tanaka |
| author_sort | Ngoc Quang Trinh |
| collection | DOAJ |
| description | The effect of flux ratio on metal transfer behavior during metal-cored arc welding was elucidated through investigation using a standard solid wire and three metal-cored wires with flux mass ratios of <b>(2-2)</b> 10%, 15%, and 20%. Investigation was performed using a shadowgraph technique based on images recorded with a high-speed camera equipped with back-laser illumination. We observed that the droplet transfer frequency increased with both the welding current and flux ratio, with the effect of flux ratio being more dominant at low currents. We surmise that this is because the wire sheath area decreases as the flux ratio is increased. Hence, when the welding current is the same, a reduction in the sheath area (i.e., an increase in flux content) leads to an increase in the current density in the sheath, which enlarges the electromagnetic force at the tip of the wire and aids droplet detachment. Conversely, Joule heating is higher at high welding currents than at low currents. This increased temperature shortens the flux column inside the wire, such that the current flow into the molten droplets is more uniform. Hence, the droplet transfer frequency does not increase significantly if the flux ratio is increased in the high current range. |
| first_indexed | 2024-03-09T10:15:06Z |
| format | Article |
| id | doaj.art-1919ca4a2bc740718dc74a40cc24b699 |
| institution | Directory Open Access Journal |
| issn | 2075-4701 |
| language | English |
| last_indexed | 2024-03-09T10:15:06Z |
| publishDate | 2022-06-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Metals |
| spelling | doaj.art-1919ca4a2bc740718dc74a40cc24b6992023-12-01T22:26:00ZengMDPI AGMetals2075-47012022-06-01127106910.3390/met12071069Effect of Flux Ratio on Droplet Transfer Behavior in Metal-Cored Arc WeldingNgoc Quang Trinh0Shinichi Tashiro1Tetsuo Suga2Tomonori Kakizaki3Kei Yamazaki4Tomokazu Morimoto5Hiroyuki Shimizu6Ackadech Lersvanichkool7Hanh Van Bui8Manabu Tanaka9Joining and Welding Research Institute, Osaka University, Osaka 567-0047, JapanJoining and Welding Research Institute, Osaka University, Osaka 567-0047, JapanJoining and Welding Research Institute, Osaka University, Osaka 567-0047, JapanKobe Steel, Ltd., Fujisawa 251-8551, JapanKobe Steel, Ltd., Fujisawa 251-8551, JapanKobe Steel, Ltd., Fujisawa 251-8551, JapanKobe Steel, Ltd., Fujisawa 251-8551, JapanThai Kobelco Welding Co., Ltd., Muang 10280, ThailandSchool of Mechanical Engineering, Hanoi University of Science and Technology, Hanoi 100-000, VietnamJoining and Welding Research Institute, Osaka University, Osaka 567-0047, JapanThe effect of flux ratio on metal transfer behavior during metal-cored arc welding was elucidated through investigation using a standard solid wire and three metal-cored wires with flux mass ratios of <b>(2-2)</b> 10%, 15%, and 20%. Investigation was performed using a shadowgraph technique based on images recorded with a high-speed camera equipped with back-laser illumination. We observed that the droplet transfer frequency increased with both the welding current and flux ratio, with the effect of flux ratio being more dominant at low currents. We surmise that this is because the wire sheath area decreases as the flux ratio is increased. Hence, when the welding current is the same, a reduction in the sheath area (i.e., an increase in flux content) leads to an increase in the current density in the sheath, which enlarges the electromagnetic force at the tip of the wire and aids droplet detachment. Conversely, Joule heating is higher at high welding currents than at low currents. This increased temperature shortens the flux column inside the wire, such that the current flow into the molten droplets is more uniform. Hence, the droplet transfer frequency does not increase significantly if the flux ratio is increased in the high current range.https://www.mdpi.com/2075-4701/12/7/1069metal-cored arc weldingmetal-cored wireflux ratiodroplet transfercurrent path |
| spellingShingle | Ngoc Quang Trinh Shinichi Tashiro Tetsuo Suga Tomonori Kakizaki Kei Yamazaki Tomokazu Morimoto Hiroyuki Shimizu Ackadech Lersvanichkool Hanh Van Bui Manabu Tanaka Effect of Flux Ratio on Droplet Transfer Behavior in Metal-Cored Arc Welding Metals metal-cored arc welding metal-cored wire flux ratio droplet transfer current path |
| title | Effect of Flux Ratio on Droplet Transfer Behavior in Metal-Cored Arc Welding |
| title_full | Effect of Flux Ratio on Droplet Transfer Behavior in Metal-Cored Arc Welding |
| title_fullStr | Effect of Flux Ratio on Droplet Transfer Behavior in Metal-Cored Arc Welding |
| title_full_unstemmed | Effect of Flux Ratio on Droplet Transfer Behavior in Metal-Cored Arc Welding |
| title_short | Effect of Flux Ratio on Droplet Transfer Behavior in Metal-Cored Arc Welding |
| title_sort | effect of flux ratio on droplet transfer behavior in metal cored arc welding |
| topic | metal-cored arc welding metal-cored wire flux ratio droplet transfer current path |
| url | https://www.mdpi.com/2075-4701/12/7/1069 |
| work_keys_str_mv | AT ngocquangtrinh effectoffluxratioondroplettransferbehaviorinmetalcoredarcwelding AT shinichitashiro effectoffluxratioondroplettransferbehaviorinmetalcoredarcwelding AT tetsuosuga effectoffluxratioondroplettransferbehaviorinmetalcoredarcwelding AT tomonorikakizaki effectoffluxratioondroplettransferbehaviorinmetalcoredarcwelding AT keiyamazaki effectoffluxratioondroplettransferbehaviorinmetalcoredarcwelding AT tomokazumorimoto effectoffluxratioondroplettransferbehaviorinmetalcoredarcwelding AT hiroyukishimizu effectoffluxratioondroplettransferbehaviorinmetalcoredarcwelding AT ackadechlersvanichkool effectoffluxratioondroplettransferbehaviorinmetalcoredarcwelding AT hanhvanbui effectoffluxratioondroplettransferbehaviorinmetalcoredarcwelding AT manabutanaka effectoffluxratioondroplettransferbehaviorinmetalcoredarcwelding |