Solid Welding Wire Composition for Cryogenic Toughness at Lower Ni Cost
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Solution Overview
Problem
Current welding technologies for Ni alloy steel at low temperatures face challenges in reducing material costs while maintaining low temperature toughness and efficiency, particularly with Ni-based alloy welding materials that are expensive and prone to defects.
Innovation Solution
A solid wire with optimized chemical composition, including reduced Ni content and specific ratios of deoxidizing elements like Mn, Al, Ti, and Ta, is used for gas shielded arc welding, such as MIG or MAG, to achieve low oxygen content and improved toughness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If Ni-based alloy welding material is used to maintain low temperature toughness, then toughness at -196°C is improved, but material cost increases significantly
Solution Approach 1:
The patent changes the chemical composition parameters by reducing Ni content from 60-80 mass% to 8-16 mass% and optimizing deoxidizing element contents (Mn: 0.05-1.80%, Al: 0.03-0.50%, Ti: 0-0.10%, Ta: 0-0.10%). This parameter optimization maintains low temperature toughness while significantly reducing material cost
Solution Approach 2:
The patent creates a composite welding material system combining reduced Ni content with optimized deoxidizing elements (Mn, Al, Ti, Ta) to achieve both cost reduction and performance maintenance. The synergistic combination of these elements compensates for reduced Ni content
2Quantity of substance
If Ni content in welding material is reduced to match Ni alloy steel level, then material cost is reduced, but oxygen content must be reduced to extremely low level to maintain toughness
Solution Approach 1:
The patent applies preliminary deoxidation by adding deoxidizing elements (Mn, Al, Ti, Ta) to the welding material composition before welding. This preliminary action reduces oxygen content in the weld metal, eliminating the need for extremely precise oxygen control during welding and enabling use of more efficient welding methods
Solution Approach 2:
The deoxidizing elements (Mn, Al, Ti, Ta) act as intermediaries that react with oxygen to form oxides, thereby removing oxygen from the weld metal. This intermediary mechanism achieves low oxygen content without requiring extremely precise control
3Strength
If TIG welding is used to reduce oxygen content in weld metal, then low temperature toughness is improved, but welding efficiency decreases
Solution Approach 1:
The patent uses consumable solid wire welding materials containing deoxidizing elements that provide oxygen removal functionality. This disposable approach to oxygen control enables use of more efficient MIG/MAG welding methods instead of TIG welding, improving welding efficiency
4Productivity
If MAG welding is used to improve welding efficiency, then welding cost is reduced, but oxygen is easily incorporated into weld metal
Solution Approach 1:
The patent applies preliminary deoxidation by incorporating deoxidizing elements (Mn, Al, Ti, Ta) into the welding material composition before welding. This preliminary action prevents oxygen incorporation issues during MAG welding, enabling use of this efficient welding method
Solution Approach 2:
The patent converts the harmful effect of oxygen incorporation during MAG welding into a benefit by using deoxidizing elements that react with oxygen to form oxides. This transforms the oxygen problem into an opportunity to achieve low oxygen content weld metal while maintaining high welding efficiency
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 solution significantly reduces welding material costs and enhances low temperature toughness of weld metals, achieving high efficiency and low cost production of welds with excellent tensile strength and Charpy absorbed energy at -196°C.
Implementation Method 1
a solid wire with optimized chemical composition, including reduced Ni content and specific ratios of deoxidizing elements like Mn, Al, Ti, and Ta, is used for gas shielded arc welding, such as MIG or MAG, to achieve low oxygen content and improved toughness
Implementation Method 2
gas shielded arc welding, such as MIG or MAG
Data Source
Figure 1~2
AI summary
A solid wire according to an aspect of the present invention contains, as a chemical composition: C: 0.003% to 0.080%; Si: 0.0010% to 0.50%; Mn: 0.050% to 1. 80%; Al: 0.030% to 0.500%; Ni: 8.0% to 16.0%; P: 0.0200% or less; S: 0.0100% or less; O: 0.050% or less; Ta: 0% to 0.1000%; Cu: 0% to 0.5%; Cr: 0% to 0.5%; Mo: 0% to 0.5%; V: 0% to 0.20%; Ti: 0% to 0.10%; Nb: 0% to 0.10%; B: 0% to 0.010%; Mg: 0% to 0.80%; REM: 0% to 0.050%; and a remainder: Fe and impurities, α is 1.35% to 5.50%, and Ceq is 0.250% to 0.520%.