• Journal of Welding and Joining
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• v.10 no.4
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• pp.190-198
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• 1992

Among the variety of welding processes available, the flux cored arc welding is one of the most frequently used process, because of its wide range of application and high productivity. The weld joint tracking is indispensable to improve the flexibility of the arc welding robot application for the flux cored arc welding (FCAW) process. In this study, an arc sensor which utilizes the electrical signal obtained from the welding arc itself was developed for weld joint tracking in FCAW. Because a model of the welding arc in flux cored arc welding was required to develop the arc sensor, a mathematical model was proposed by analysing the welding arc behaviour, and also an experimental model by using the factorial experiment and least square method. For overcoming the fluctuation in the welding current signal during tracking the weld joint, it was fitted to a curve which is inversely proportional to a trace of tip-to-workpiece distance by using the quadratic curve-fitting method.

• International Journal of Korean Welding Society
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• v.1 no.1
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• pp.71-77
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• 2001

The characteristics of the fume generation in a flux cored arc welding were investigated using the fume collection chamber developed. The Korean Standard concerning the method for the evaluation of the fume generation rate(FGR) was updated by the evaluation method obtained through this study. It was found that the effect of humidity in the test environment should be considered and the automatic welding method had to be employed for the purpose of the exact evaluation of the fume generation rate. The results showed that the fume generation rate was influenced by the welding parameters. The important factors were the welding current arc voltage, travel speed, and contact tip to work distance(CTWD) that affected the heat input as well as the torch angle and the shielding gas flow rate that influenced the shielding effect. The fume generation rate increased as the heat input increased and the shielding effect decreased. It was also observed that the effect of the welding current is much grater than the other welding parameters.

• Journal of Welding and Joining
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• v.3 no.1
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• pp.40-45
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• 1985

Wire meling characteristics were examined with variation of gas formers such as $MgCO_3, CaCO_3 and Li_ 2CO_ 3$ by self-shielded flux cored arc welding. The flux cored wire of overlap type was welded by DCRP. The results obtainedareas follows. 1) Drop type was observed with no gas former, repelled type with MgCO_3$ added and short circuit type with $Li_2CO_3$ added. The variation of transfer mode was related to the blowing force of $CO_2$ gas and the surface tension of the slag. 2) Droplet size increased with adding gas formers due to the effect of $CO_2$ gas cushion. 3) Core spikes were observed more frequently with increasing the amount of gas formers.

• Journal of Welding and Joining
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• v.34 no.6
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• pp.1-10
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• 2016

Flux Cored Wire is the most widely used welding material for Flux Cored Arc Welding these days. This paper introduces the technical aspects of manufacturing FCW and the development trend of FCW for each type of steel and metal. The studies are ongoing to lower the production cost of seamless-type FCW since it has not been generally used in welding shops so far because of it high cost even though the seamless-type FCW has various advantages than folded-type FCW in terms of manufacturing technology. Meanwhile, a technical research has been carried out to develop a rutile type of FCW products which satisfies high toughness after post heat treatment. In addition, for high-speed fillet welding, there has been a development of welding materials which can be welded in Single Auto-Carriage 100 cpm or more and up to Twin Tandem 200 cpm without occurring any welding defect in order to improve the welding productivity. As Zn coated steel is being used recently to improve the corrosion resistance of the automotive parts, a research and development for Metal Cored Wire has been conducted to reduce the Si island produced in welding operation than those produced when using the former solid wires. A development of welding material that guarantees CTOD performance beyond $-40^{\circ}C$ CTOD to $-60^{\circ}C$ is underway by different steel grades, and FCW for super austenitic stainless steel is being developed as the corrosion resistant steel has been upgraded.

• Journal of Welding and Joining
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• v.31 no.4
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• pp.42-46
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• 2013

The contact tip for flux cored arc welding has important functions to transmit the welding current to the wire and to guide the wire to molten pool. A damaged contact tip causes a productivity reduction and a welding quality problem. In this study, the welding experiments for the wear resistance of contact tip regarding flux cored wire types were performed. With two fold type and a seamless type flux cored wires, the wear rates of contact tips were compared. In addition, the wear rate was checked according to the contact tip position.

• Journal of Ocean Engineering and Technology
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• v.27 no.5
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• pp.77-81
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• 2013

The effects of the welding parameters, contact tip-to-workpiece distance (CTWD), current, and voltage on the diffusible hydrogen content in weld metal deposited by self-shielded flux cored arc welding were investigated and rationalized by comparing the amount of heat generated in the extension length of the wire. This showed that as CTWD increased from 15mm to 25mm, the amount of heat generated was increased from 71.1J to 174.8J, and the hydrogen content was decreased from 11.3mL/100g to 5.9mL/100 g. Even if little difference was observed in the amount of heat generated, the hydrogen content was increased with an increase in voltage because of the longer arc length. A regression analysis showed that the regression coefficient of voltage in self-shielded flux cored arc welding is greater than that in $CO_2$ arc welding. This implies that voltage control is more important in self-shielded flux cored arc welding than in $CO_2$ arc welding.

• Journal of Welding and Joining
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• v.16 no.5
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• pp.93-99
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• 1998

Effects of gas formers of MgCO$_3$, CaCO$_3$ and Li$_2$CO$_3$ on the spattering phenomena were investigated for non-shielded flux cored arc welding. Spattering phenomena were pictured using high speed camera as a speed of 3000 frames per sec. As experimental results, spattering modes were classified into 4 types. The modes were spattering by arc force, gas explosion, short circuit and pore escape. The amount of spatters by arc force was 30%, gas blowing force was 40%, short circuit 10%, pore escape was 10% and others were 10%. When Li$_2$CO$_3$ was added, the amount of spatters was largest, and it decreased in the order of CaCO$_3$ and MgCO$_3$.

• Journal of Welding and Joining
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• v.1 no.2
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• pp.76-82
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• 1983

The chemical composition of deposit metal by flux cored arc welding can be easily regulated though addition of deoxidizers and alloying elements in cored flux and fluxes of flux coored wire arc analogous to those of coated electrode. It is necessary to investigate the transfer and yield efficiency due to addition of necessary alloy elements in deposit metal. This report is made to intorduce an experimental equation from the relation between welding condition and extent of penetration, deposit metal and weld melt slag and to estimate transfer and yield efficiency of alloy components in fluxes through chemical analysis of deposit metal.

• Journal of Environmental Health Sciences
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• v.25 no.3
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• pp.108-112
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• 1999

A study was conducted for the effects of input energy on fume formation ratios based on electrode(FFR$_{electrode}(g/kg_{electrode})),\;deposited\;metal(FFR_{weld}(g/kg_{weld}))\;and\;slag(FFR_{slag}(g/kg_{slag}))\;at\;CO_2$ flux cored arc welding on stainless steel. Experiments were run in well designed welding fume box. Six types of flux cored wires were used and three levels of current and voltages were given. The measured values of $FFR_{electrode},\;FFR_{weld},\;FFR_{slag}\;are\;7.90{\pm}1.47\;g/kg_{electrode},\;9.18{\pm}1.65\;g/kg_{\electrode},\;71.8{\pm}24.2\;g/kg_{slag}$ respectively. Fume formation ratios are not increased dramatically by input energy because of simultaneous increasing of melted electrodes, deposited metal and slag. The results indicate that the test of fume formation ratios in the research on production of low fume welding wire can be run at the fixed condition of input energy rather than various condition.

• Journal of Welding and Joining
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• v.34 no.2
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• pp.16-21
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• 2016

Recent keywords of the heavy industries are large-scale structure and productivity. Especially, the sizes of the commercial vessels and the offshore structures have been gradually increased to deliver goods and explore or produce oil and natural gas in the Arctic. High heat input welding processes such as electro gas welding (EGW) have been widely used for welding thick steel plates with flux-cored arc welding (FCAW), especially in the shipbuilding industries. Because high heat input welding may cause the detrimental effects on the fracture toughness of the welded joint and the heat affected zone, it is essential to obtain the sufficient toughness of welded joint. There are well known that the fracture toughness like CTOD, CVN, and KIC were very important factors in order to secure the safety of the structures. Furthermore, the welding residual stress should be considered to estimate the unstable fracture in both EGW and FCAW. However, there are no references on the welding residual stress distribution of EGW and FCAW with thick steel plates. Therefore the welding residual stresses were very important elements to evaluate the safety of the welded structure. Based on the measurement results, the characteristics of residual stress distribution through thickness were compared between one-pass electron gas welding and multi-pass flux-cored arc welding. The longitudinal residual stress in the multi-pass flux-cored arc welding is tensile through all thicknesses in the welding fusion zone. Meanwhile, longitudinal residual stress of EGW is tensile on both surfaces and compressive at the inside of the plate. The magnitude of residual stresses by electron gas welding is lower than that by flux-cored arc welding.