Solid Wire Composition for Arc Welding Burn-Through Resistance
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Solution Overview
Problem
Arc welding of high-strength steel sheets faces challenges such as burn-through, undercut, and hot cracking due to increased tensile strength and element additions, which degrade weld quality and increase costs, while existing solutions like small-diameter wires and specialized shielding gases lead to stability issues and cost increments.
Innovation Solution
A solid wire with specific compositions of C, Si, Mn, P, S, O, N, and impurities, optimized to reduce viscosity and surface tension of the molten pool, combined with surface treatments like copper plating and MoS2 coating, to enhance burn-through and undercut resistance and prevent cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the amount of elements (Si, Mn, etc.) is increased to achieve high strength steel sheet, then tensile strength is improved, but viscosity of molten pool is increased, blendability is degraded, and undercut occurs
Solution Approach 1:
The invention changes the chemical composition parameters of the solid wire by precisely controlling the content ranges of C (0.10-0.25%), Si (0.50-1.50%), Mn (1.00-2.00%), and other elements. This parameter optimization reduces molten pool viscosity and surface tension, improving blendability and preventing undercut while maintaining high strength properties in the welded joint.
2Productivity
If welding speed is increased to improve welding efficiency, then productivity is improved, but arc directly impinges upon molten surface, causing burn through
Solution Approach 1:
The invention optimizes the chemical composition parameters of the solid wire, particularly controlling C (0.10-0.25%), Si (0.50-1.50%), and Mn (1.00-2.00%), which modifies the thermal and fluid properties of the molten pool. This enables stable welding at higher speeds by preventing arc penetration and burn through, thereby improving productivity without sacrificing joint quality.
3Object-affected harmful factors
If small diameter wire (0.9 mm or less) is used to decrease input heat per deposition, then burn through resistance is improved, but wire feed stability is degraded and welding cost increases
Solution Approach 1:
The invention changes the chemical composition parameters of the solid wire (C: 0.10-0.25%, Si: 0.50-1.50%, Mn: 1.00-2.00%, and controlled impurities) to optimize physical properties such as electric resistivity and surface tension. This enables the use of standard diameter wires with stable feed characteristics while achieving improved burn through resistance through controlled heat input and enhanced molten pool fluidity.
4Object-affected harmful factors
If Ar is mixed with O2 gas to improve burn through resistance, then burn through resistance is improved, but shielding gas cost increases
Solution Approach 1:
The invention changes the composition parameters of the solid wire, optimizing C (0.10-0.25%), Si (0.50-1.50%), Mn (1.00-2.00%), and other elements to inherently improve burn through resistance. This eliminates or reduces the need for expensive O2-containing shielding gas mixtures, achieving the same protective effect through material composition control rather than costly gas additives.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solid wire achieves improved burn-through and undercut resistance, reduced spatter and slag production, and increased weld metal hardness, maintaining cost-effectiveness while ensuring stability and crack resistance.
Implementation Method 1
optimized to reduce viscosity and surface tension of the molten pool
Implementation Method 2
optimized to reduce viscosity and surface tension of the molten pool
Implementation Method 3
surface treatments like copper plating
Implementation Method 4
MoS2 coating
Data Source
AI summary
A solid wire contains C of 0.020 to 0.100 mass percent, Si of 0.25 to 1.10 mass percent, Mn of 1.20 to 1.65 mass percent, P of 0.008 to 0.017 mass percent, S of 0.045 to 0.150 mass percent, O of 0.0050 mass percent or less, N of 0.0050 mass percent or less, wherein P*(O+N)*105≦15 is satisfied, and the remainder including Fe and impurities, wherein the relevant impurities contain Ti of 0.15 mass percent or less, B of 0.0050 mass percent or less, and Cr, Ni, Al, Nb, V, Zr, La and Ce of 0.20 mass percent or less respectively. According to such a configuration, a solid wire is provided, in which while increase in welding cost is controlled to the minimum, stability of wire feed, burn-through resistance, undercut resistance, and crack resistance are excellent, slag and spatter are hardly produced, hardness of weld metal is equal to or higher than that of base metal, and brittle fracture hardly occurs.