Welding Wire Composition for Slag Control in High-Strength Steel
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Solution Overview
Problem
Conventional welding of high-strength steel generates slag that interferes with electrodeposition painting and deteriorates the anti-corrosive performance of welded portions, making it difficult to remove and leading to stability issues in large structures.
Innovation Solution
A welding wire composition with specific weight percentages of C, Mn, Si, Al, Se, and S, which generates Al—Mn—Si-based crystalline oxides with low surface energy, minimizing slag generation and facilitating its removal by inducing molten pool flow to the center of the weld bead, thereby improving paintability and anti-corrosive performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional welding wire is used for welding high-strength steel, then welding can be performed, but slag is generated and remains in the toe portion between weld bead and base material
Solution Approach 1:
The patent changes the chemical composition parameters of the welding wire by precisely controlling the content ranges of C (0.09-0.11%), Mn (0.20-0.40%), Si (0.30-0.65%), Al (0.03-0.04%), S (0.05-0.07%), and Se (0.005-0.01%). This parameter optimization modifies the slag generation characteristics and molten pool fluidity, enabling the slag to be naturally expelled from the toe portion during welding, thereby resolving the contradiction between maintaining welding reliability and reducing harmful slag generation.
2Ease of manufacture
If slag remains in the toe portion after welding, then the welding structure is formed, but paintability and anti-corrosive performance deteriorate
Solution Approach 1:
The patent optimizes the chemical composition parameters to control slag generation and molten pool behavior. By adjusting C, Mn, Si, Al, S, and Se content within specific ranges, the slag is transformed into a form that is easily removable, and the molten pool flows to concentrate slag at the center rather than the toe portion. This resolves the contradiction by enabling easy slag removal while maintaining welding processability, thereby improving subsequent paintability and anti-corrosive performance.
3Productivity
If slag is not removed from the toe portion, then the welded structure is completed, but the stability of large structures deteriorates
Solution Approach 1:
The patent modifies the chemical composition parameters of the welding wire to fundamentally change the slag behavior during welding. The optimized content ranges of C (0.09-0.11%), Mn (0.20-0.40%), Si (0.30-0.65%), Al (0.03-0.04%), S (0.05-0.07%), and Se (0.005-0.01%) create a molten pool with improved fluidity that naturally expels slag from the toe portion. This resolves the contradiction by maintaining high welding efficiency while automatically ensuring structure stability through slag removal, eliminating the need for post-welding slag removal operations.
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 slag remaining in the toe portion by about 80%, enhancing the mechanical and anti-corrosive properties of welded portions and improving paintability, thus extending the lifespan of structures.
Implementation Method 1
an Al—Mn—Si-based crystalline oxide may be generated from slag resulting from a welding process
Implementation Method 2
generates Al—Mn—Si-based crystalline oxides with low surface energy
Implementation Method 3
the pool is capable of flowing to a center portion in a width direction of a weld bead, thereby allowing a generated slag to be concentrated on the center portion
Data Source
AI summary
A welding wire for high-strength steel for improving slag coagulation includes a combination of Carbon, Manganese, Silicon, Aluminum, Sulfur, and Selenium. With use of the welding wire, the generation of slag is minimized, and the slag is allowed to induce the generation of crystalline oxides having a low surface energy, so that the slag is easily removed, and the flow of a molten pool to the center in a width direction of a weld bead do that the slag is coagulated.