Granular Weld Flux with Controlled Titanium and Boron
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Solution Overview
Problem
Existing welding flux systems require reheating to achieve high toughness weld metal and face difficulties in slag removal due to high titanium levels, which complicates the process and reduces the hardness of top weld layers.
Innovation Solution
A granular flux system with controlled amounts of titanium and boron, formulated to transfer these elements efficiently into the weld metal without using aluminum to remove oxygen and nitrogen, thereby preventing unwanted reactions and facilitating easy slag removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high levels of titanium are added to the flux system to achieve necessary weld metal toughness, then toughness is improved, but slag removal from the weld metal becomes significantly more difficult
Solution Approach 1:
The patent changes the chemical composition parameters by using a rutile-based slag system with controlled titanium dioxide content (10-40% by weight) and specific ratios of other oxides (CaO, SiO2, Al2O3, MnO, MgO, TiO, B2O3) to achieve the optimal balance between weld metal toughness and slag removal ease, reducing titanium deposition to below 20 ppm while maintaining high toughness
Solution Approach 2:
The patent creates a composite flux system combining multiple oxide components (rutile, lime, silica, alumina, manganese oxide, magnesium oxide, titanium monoxide, boron oxide) in specific proportions to form a slag system that simultaneously provides toughness enhancement and facilitates slag removal, with the composite composition controlling titanium transfer to the weld metal
2Strength
If small amounts of titanium and boron are added to a basic flux to obtain fine grain structure and high toughness, then weld metal toughness is improved, but the flux system becomes more complex and difficult to control
Solution Approach 1:
The patent makes the flux system multi-functional by using a rutile-based slag system that simultaneously achieves grain refinement, toughness enhancement, and slag removal facilitation through its composite composition, eliminating the need for separate additives and simplifying the overall flux formulation while maintaining high toughness and fine grain structure
Solution Approach 2:
The patent optimizes the composition parameters of the flux system by specifying precise weight percentage ranges for each component (titanium dioxide: 10-40%, calcium oxide: 10-30%, silicon dioxide: 10-30%, aluminum oxide: 5-20%, manganese oxide: 1-10%, magnesium oxide: 1-10%, titanium monoxide: 0.1-5%, boron oxide: 0.1-5%) to achieve the desired balance between toughness, grain structure, and system controllability
3Shape
If titanium and boron are added to a non-rutile based flux system, then fine grain size is achieved, but the ratio of titanium to boron must be maintained at least 10:1 which results in poor slag removal
Solution Approach 1:
The patent changes the titanium to boron ratio parameter from the conventional 10:1 minimum to a controlled range within the composite rutile-based system, where titanium dioxide is 10-40% and boron oxide is 0.1-5%, achieving a balanced ratio that simultaneously produces fine grain size and facilitates slag removal by controlling titanium deposition to below 20 ppm
Solution Approach 2:
The patent uses a composite rutile-based slag system that combines titanium dioxide with other oxides in specific proportions to modify the behavior of titanium and boron additions, enabling fine grain structure formation while improving slag removal characteristics through the synergistic effect of the composite composition
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 flux system achieves high toughness weld metal without reheating and ensures easy slag removal, maintaining the effectiveness of boron while reducing titanium levels to improve process efficiency and weld quality.
Implementation Method 1
an electric arc between the wire and workpiece melts the advancing wire and deposits a weld metal onto the workpiece
Implementation Method 2
The flux is at least partially melted during the welding process and forms a slag over the top of the molten metal deposited on the workpiece
Data Source
AI summary
A granular flux having controlled amounts of titanium and boron to facilitate in the formation of a weld metal having a high toughness without requiring refinement of the weld metal by reheating the weld metal, and enabling the slag to be easily removed from the weld bead.