Modification of Flux Oxygen Behaviour via Co-Cr-Al Unconstrained Metal Powder Additions in Submerged Arc Welding: Gas Phase Thermodynamics and 3D Slag SEM Evidence

Aluminium metal is avoided as main reactant in submerged arc welding (SAW) because it is easily oxidised in this process. Aluminium is an effective de-oxidiser and can be used to prevent Cr and Co loss to the slag by preventing oxidation of these metals. In our novel application of aluminium metal powder in SAW we demonstrate the modification of flux oxygen behaviour. The Co-Cr-Al-alloyed weld metal total oxygen content is decreased to 180 ppm O, compared to 499 ppm O in the weld metal from the original flux, welded without metal powder additions. The flux oxygen behaviour is modified by the added aluminium powder through the lowering of the original flux-induced partial oxygen pressure in the arc cavity and at the molten flux-weld pool interface. Carbon steel was alloyed to 5.9% Co, 6.3 % Cr and 5.1% Al at 81% Co yield, 87% Cr yield and 70% Al yield. Gas-slag-alloy thermochemical equilibrium calculations confirm the partial oxygen-pressure-lowering effect of aluminium. BSE (backscattered electron) images of the three-dimensional (3D) post-weld slag sample show dome structures which contain features of vapour formation and re-condensation. These features consist of small spheres (sized less than 10 μm) and smaller needle-shaped particles coalescing into a porous sphere. EDX analyses show that the spheres consist of Si-Na-K-Fe-Mn-Co-Cr oxy-fluoride and the needles consist of low oxygen Si-Al-Ca-Mg-Na-K-Fe-Mn-Co-Cr oxy-fluoride. The element distribution and speciation data from the EDX analyses confirm modification of the flux oxygen behaviour via aluminium powder addition in lowering the partial oxygen pressure, which in turn prevents oxidation of Cr and Co and minimise losses to the slag.