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Design and development of welding electrode for structural steel

  • K. Kumar , L. Sharma

    Graduated at Beant College of Engineering & Technology Gurdaspur (State Govt. College) in 2008. Worked at Tharrmax Ltd. from 2008 to 2009. Completed his M.Eng. at Thapar University Patiala in 2011. Assistant Professor at Lovely Professional University from 2011 to 2015. PhD from IIT Jodhpur in 2020. Assistant Professor in Chandigarh University since 2020

     EMAIL logo     , R. Chhibber , S. K. Mohapatra and R. K. Sharma
Published/Copyright: February 21, 2025
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Practical Metallography
From the journal Practical Metallography Volume 62 Issue 3

Abstract

Due to the large number of consumables available, the flexibility required to achieve appropriate properties in the welded joint is very high. Fundamental knowledge about development of different electrodes for structural steel, of which information is scarce in international welding literature. In present work six rutile coated electrodes were prepared by increasing calcite content, at the expense of cellulose and Si-bearing components like mica and china clay, in the fluxes. This modification produced an increase in the slag basicity, which caused a marked increment in all-weld-metal toughness and modifications in operational behavior with a decrease in penetration and width of the weld bead, while maintaining the typical excellent operational characteristics of rutile electrodes. Microstructure examination of six electrodes indicates the presence of inclusions and secondary phase particles. Maximum tensile strength of 430 N/mm2 while minimum tensile strength of 323 N/mm2 was observed for 7.5 % and 12.5 % calcite content. In F position, 7.5 %, 10 %, 12.5 % calcite was faster than 15 %, 17.5 % and 20 % calcite. For DC (+), 15 %, 17.5 %, 20 % calcite presented higher spatter than 5 %, 10 %, 12.5 % calcite.

Kurzfassung

Aufgrund der Vielzahl an verfügbaren Verbrauchsmaterialien und Verfahren besteht eine hohe Flexibilität hinsichtlich der Erzeugung von Schweißnähten mit geeigneten Eigenschaften. In der internationalen Schweißliteratur ist jedoch nur wenig über die Grundlagen zur Entwicklung verschiedener Stabelektroden für Baustahl zu finden. Für die vorliegende Arbeit werden sechs rutilumhüllte Elektroden hergestellt, bei denen der Calcitgehalt erhöht und der Gehalt an zellulose- und Si-haltigen Bestandteilen wie Glimmer und Kaolinit in den Flussmitteln entsprechend verringert wird. Diese Modifikation führte zu einer höheren Basizität der Schlacke und damit zu einem deutlichen Anstieg der Zähigkeit des Schweißguts und einer Änderung des Betriebsverhaltens. Ebenso wurde eine Verringerung der Einbrandtiefe und der Breite der Schweißraupe beobachtet, während die für rutilumhüllte Elektroden typischen ausgezeichneten Betriebseigenschaften erhalten blieben. Gefügeuntersuchungen der sechs Elektroden weisen auf das Vorliegen von Einschlüssen und Partikeln der Sekundärphase hin. Bei Calcitgehalten von 7,5 % und 12,5 % wurde eine maximale Zugfestigkeit von 430 N/mm2 und eine minimale Zugfestigkeit von 323 N/mm2 beobachtet. Beim Schweißen in Wannenposition wurde mit Calcitgehalten von 7,5 %, 10 % und 12,5 % eine höhere Schweißgeschwindigkeit als mit Gehalten von 15 %, 17,5 % und 20 % erzielt. Bei Gleichstrom mit positiver Elektrodenpolung (DC (+)) wurden mit Calcitgehalten von 15 %, 17,5 % und 20 % mehr Schweißspritzer als bei Gehalten von 5 %, 10 % und 12,5 % beobachtet.

Keywords: SMAW; electrode; basicity; index; slag; toughness
Schlagwörter: Lichtbogenhandschweißen; Elektrode; Basizität; Schlacke; Zähigkeit

About the author

L. Sharma

Graduated at Beant College of Engineering & Technology Gurdaspur (State Govt. College) in 2008. Worked at Tharrmax Ltd. from 2008 to 2009. Completed his M.Eng. at Thapar University Patiala in 2011. Assistant Professor at Lovely Professional University from 2011 to 2015. PhD from IIT Jodhpur in 2020. Assistant Professor in Chandigarh University since 2020

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Received: 2024-02-26
Accepted: 2024-07-22
Published Online: 2025-02-21
Published in Print: 2025-02-25

© 2025 Walter de Gruyter GmbH, Berlin/Boston

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  2. Editorial
  3. Editorial
  4. Effect of tramp elements on the microstructural evolution of a ferritic-pearlitic steel
  5. Deep learning in metallography: adapting a grain size determination model to develop the new comparison charts for ISO 643
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  9. Picture of the Month
  10. Picture of the Month
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https://doi.org/10.1515/pm-2025-0003
Keywords for this article
SMAW; electrode; basicity; index; slag; toughness

Articles in the same Issue

  1. Inhalt
  2. Editorial
  3. Editorial
  4. Effect of tramp elements on the microstructural evolution of a ferritic-pearlitic steel
  5. Deep learning in metallography: adapting a grain size determination model to develop the new comparison charts for ISO 643
  6. Design and development of welding electrode for structural steel
  7. Failure Analysis
  8. Metallurgical failure analysis of small-bore tube compression fitting that fractured in a gas turbine burner test rig
  9. Picture of the Month
  10. Picture of the Month
  11. News
  12. News
  13. Meeting Diary
  14. Meeting Diary
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