Application of a complete factorial experiment to optimize the filling factor and charge density of the self-shielding flux-cored wire

Keywords

self-shielded flux-cored wire, factorial design, filling rate, core filler density, exothermic addition.

Cite as

Trembach І. O., Trembach B. O., Grin A. G., Luzhetskyy R. Ya., Brechko V. A., Zakovorotniy A. Yu., Balenko O. I., Molchanov H. I., Rebrova О. М., and Kabatskyi O. V. Application of a complete factorial experiment to optimize the filling factor and charge density of the self-shielding flux-cored wire. Physicochemical Mechanics of Materials. 2024. 60(4), 052-059.

https://doi.org/10.15407/pcmm2024.04.052

Abstract

The necessity to study such characteristics of self-shielding flux-cored wire as the filling rate (C_WF) and core filler density (r_сf) is grounded. The influence of the exothermic addition content, exothermic addition components ratio, graphite content on the filling rate (C_WF) and filler density (r_сf) was studied using Fractional Factorial Design, the mathematical models are built. It is shown that the content of exothermic addition (C_EA) and graphite (С_graphite) in the charge has the greatest influence on the filling rate (C_WF). Maximum values C_WF and density r_сf are obtained with the following characteristics: C_EA = 20–28 wt%, MnO₂/Al = 2–2.8 and С_graphite = 4–6 wt%.

References

1. V. Lozynskyi, B. Trembach, M. M. Hos¬sain, Y. Silchenko, M. Krbata, K. Sadovyi, O. Kolomiitse, and L. Ropyak, “Prediction of phase composition and mechanical properties Fe-Cr-C-B-Ti-Cu hardfacing alloys: modeling and experimental validations,” Heliyon, 10, Is. 3 (2024). Article number e25199. https://doi.org/10.1016/j.heliyon.2024.e25199
2. 2. O. O. Ivanov, P. M. Prysiazhniuk, L. G. Bodrova, G. M. Kramar, S. Yu. Marynenko, I. V. Koval, and O. Ya. Guryk, “3D modeling of the structure of deposited materials based on Fe-Ti-Mo-B-C system,” Mater. Sci., 59, No. 2, 163-169 (2023). https://doi.org/10.1007/s11003-024-00758-x
3. M. Student, A. Vojtovych, H. Pokhmurska, O. Student, and P. Maruschak, “Mechanical characteristics and wear resistance of the cladding layers obtained by melting of cored wires with simultaneous vibration of substrate,” Strojnicky Casopis, 69, Is. 1, 109-122 (2019). https://doi.org/10.2478/scjme-2019-0009
4. I. O. Ryabtsev, A. A. Babi¬nets, I. P. Lentyuhov, I. L. Bohaychuk, and A. V. Yevdokimov, “Influence of pulse arc surfacing modes on geometric dimensions of welded beads and struc-ture of deposited metal of Fe-C-Cr-Ti-Mn-Si alloying system,” Metallofizika i Noveishie Tekhnologii [in Russian], 43, Is. 12, 1667-1681 (2021). https://doi.org/10.15407/mfint.43.12.1667
5. M. M. Student, S. I. Markovych, V. М. Hvozdetskyi, О. S. Kalakhan, and V. M. Yuskiv, “Abrasive wear resistance and tribological characteristics of electrometallized composite coatings,” Mater. Sci., 58, No. 1, 96-104 (2022). https://doi.org/10.1007/s11003-022-00636-4
6. M. Student, V. Hvozdetskyi, T. Stupnytskyi, O. Student, P. Maruschak, O. Prent¬kovskis, and P. Skačkauskas, “Mechanical properties of arc coatings sprayed with cored wires with different charge com¬positions,” Coatings, 12, Is. 7 (2022). Article number 925. https://doi.org/10.3390/coatings12070925
7. T. R.Stupnyts’kyi, M. M. Student, H. V. Pokhmurs’ka, and V. M. Hvozdets’kyi, “Optimization of the chromium content of powder wires of the Fe-Cr-C and Fe-Cr-B systems according to the corrosion resistance of electric-arc coatings,” Mater. Sci., 52, No. 2, 165-172 (2016). https://doi.org/10.1007/s11003-016-9939-8
8. G. M. Grigoren¬ko, L. I. Adeeva, A. Y. Tunik, V. N. Korzhik, and M. V. Karpets, “Plasma arc coatings produced from powder-cored wires with steel sheaths,” Powder Metallurgy and Metal Ceramics, 59, Is. 5-6, 318-329 (2020). https://doi.org/10.1007/s11106-020-00165-2
9. М. М. Student, H. V. Pokhmurs’ka, K. R. Zadorozhna, H. H. Veselivska, V. М. Hvozdets’kyi, and Y. Y. Sirak, “Corrosion resistance of VC-FeCr and VC-FeCrСо coatings obtained by supersonic gas-flame spraying,” Mater. Sci., 54, No. 4, 535-541 (2019). https://doi.org/10.1007/s11003-019-00214-1
10. B. Trembach, O. Balenko, V. Davydov, V. Brechko, I. Trembach, and O. Kabatskyi, “Prediction the melting characteristics of self-shielded flux cored arc welding (FCAW-S) with exothermic addition (CuO-Al),” in: Proc. IEEE 4th Int. Conf. on Modern Electrical and Energy System (MEES), Kremenchuk (2022), pp. 01-06. https://doi.org/10.1109/MEES58014.2022.10005657
11. V. Lozynskyi, B. Trembach, E. Katinas, K. Sadovyi, M. Krbata, O. Balenko, I. Krasnoshapka, O. Rebrova, S. Knyazev, O. Kabatskyi, H. Kniazieva, and L. Ropyak, “Effect of exothermic additions in core filler on arc stability and microstructure during self-shielded, flux-cored arc welding,” Crystal, 14 (2024). Article number 335. https://doi.org/10.3390/cryst14040335
12. B. O. Trembach, D. B. Hlushkova, V. M. Hvozdetskyi, V. A. Vynar, V. I. Zakiev, O. V. Kabatskyi, D. B. Savenok, and O. Yu. Zakavorotnyi, “Prediction of fill factor and charge density of self-shielding flux-cored wire with variable composition,” Mater. Sci., 59, No. 1, 18-25 (2023). https://doi.org/10.1007/s11003-023-00738-7
13. E. Yamamoto, K. Yamazaki, K. Suzuki, and F. Koshiishi, “Effect of flux ratio in flux-cored wire on wire melting behaviour and fume emission rate,” Welding in the World, 54, 154-159 (2013). https://doi.org/10.1007/BF03263501
14. N. Q. Trinh, S. Tashiro, T. Suga, T. Kakizaki, K. Yamazaki, T. Morimoto, H. Shimizu, A. Lersvanichkool, H. V. Bui, and M. Tanaka, “Effect of flux ratio on droplet transfer behavior in metal-cored arc welding,” Metals, 12, Is. 7 (2022). Article number 1069. https://doi.org/10.3390/met12071069
15. О. V. Sukhova, “The effect of carbon content and cooling rate on the structure of boron-rich Fe-B-С alloys,” Physics and Chemistry of Solid State, 21, Is. 2, 355-360 (2020). https://doi.org/10.15330/pcss.21.2.355-360
16. W. Sawczuk, A. Merkisz-Guranowska, D. Ulbrich, J. Kowalczyk, and A.-M. Rilo Canas, “Investigation and modelling of the weight wear of friction pads of a railway disc brake,” Materials, 15, Is. 18 (2022). Article number 6312. https://doi.org/10.3390/ma15186312
17. D. B. Hlushkova, V. M. Volchuk, P. M. Polyansky, V. A. Saenko, and A. A. Efimenko, “Fractal modeling the mechanical properties of the metal surface after ion-plasma chrome plating,” Funct. Mater., 30, Is. 2, 275-281 (2023). https://doi.org/10.15407/fm30.02.275
18. X. Zhang, N. Guo, C. Xu, H. Kan, Y. Tan, and H. Chen. “Effect of filling rate on underwater wet welding process and weld appearance,” Materials, 13, № 5 (2020). Article number 1061. https://doi.org/10.3390/ma13051061