Automatic Welding, 2025, №02

2025 №02 (04)

2025 №02 (06)

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"Avtomatychne Zvaryuvannya" (Automatic Welding), #2, 2024, pp. 38-44

Methodology for evaluating the welding and technological properties of flux-cored wires for arc surfacing

A.A. Babinets, I.O. Ryabtsev, I.P. Lentyugov

E.O. Paton Electric Welding Institute of the NAS of Ukraine 11 Kazymyr Malevych Str., 03150, Kyiv, Ukraine. E-mail: E-mail: a_babinets@ukr.net

An analysis of existing methods for evaluating the welding and technological properties of electrode materials used in electric arc surfacing and welding has been conducted. The fundamental principles for assessing the stability of the arc process have been reviewed. The key approaches to studying the properties of electrode materials and the list of controlled parameters most frequently used for this purpose have been determined. It has been demonstrated that quantitative evaluation criteria are more advantageous compared to qualitative ones. Based on the analysis, a comprehensive methodology for evaluating the welding and technological properties of flux-cored wires has been developed, comprising three main components. The first component includes a visual expert assessment of the arc surfacing process and the quality of the deposited metal formation, performed using a differential scoring system. The second component focuses on evaluating the melting characteristics of flux-cored electrode wires based on experimentally determined melting rates, deposition rates, and material loss coefficients. The third component involves assessing the stability of the arc process, which is conducted using experimentally determined coefficients of variation for current and voltage fluctuations on the arc. The advantages of the proposed comprehensive methodology have been demonstrated through the evaluation of real flux-cored wires for arc surfacing. It has been established that this methodology provides more informative results compared to approaches relying solely on qualitative indicators. The study confirmed that the type and particle size distribution of metallic components in the core of flux-cored wires significantly influence the stability of the arc surfacing process. The use of chemically more pure and more homogeneous metallic granular powders in the flux-cored wire core, compared to ferroalloy powders, improves the stability and efficiency of the surfacing process by 15–30%. 19 Ref., 2 Tabl., 2 Fig.
Keywords: arc surfacing, flux-cored wire, deposited metal, welding and technological properties, surfacing stability, coefficients of variation


Received: 24.01.2025
Received in revised form: 26.02.2025
Accepted: 03.04.2025

References

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