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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
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