Assessing metal transfer stability and spatter severity in flux cored arc welding

Five experimental basic type flux cored arc welding consumable wire electrodes were manufactured from the same base formulation. The composition of these electrodes was adjusted in an attempt to improve the operating performance. This involved additions of various ratios of alkali oxides, namely, lithium, magnesium, sodium, and potassium containing ingredients, in the flux formulations. The operating behaviours of these experimental electrodes and two reference products (i.e. one commercial basic T–5 and one commercial rutile T–1 electrode) were thoroughly investigated by recording welding arc signals using a high speed data acquisition system. By comparing these electrodes among themselves, the experimental electrodes were reported to exhibit extremely stable arcs, some showing electrical arc signals even smoother than those for the reference rutile grade electrode. Despite their improved metal transfer consistency, however, basic electrodes were characterised by somewhat higher spatter levels.