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Home Uzbekistan Technologies Highly Effective Resource–Saving Welding Technologies and Materials for Structural Metals and Alloys

Highly Effective Resource–Saving Welding Technologies and Materials for Structural Metals and Alloys

Description

The offered technologies deal with the use of special fluxes and flux tapes at fusion welding (TIG, MIG, Laser welding, etc.) of structural metals and alloys, such as: aluminium alloys, all types of steels, titanium and its alloys, as well as nickel based alloys. The fluxes and technology of their application depend on the origin of welded metals, their thickness and configuration, as well as the welding technique. So, for fusion welding of weldments of aluminium alloys with thickness of plates no more than 4 mm it is offered to use fluxes (applied either by brush or aerosol can) applied to the back side of welded edges while for welding of articles of aluminium alloys with thickness of plates more than 4 mm it is offered to use fluxes tapes applied from the back side of the welds. This allows improving quality, mechanical and operating properties of welds. For welding of aluminium weldments with thickness of plates up to 8 mm in thickness with application of inert gas medium for one pass welding without welding edge preparation it is recommended to apply fluxes from the face side of the welds, this improves penetration ability of the welding arc, cleans molten pool from oxide films and protects puddle from harmful effect of environment. Similar technology may be very effective for welding of other structural metals and alloys, but in that case flux composition should be adapted to specific metal or an alloy being welded. Fusion welding technologies with application of flux allow obtaining welded joints of high quality with substantial cost reduction of welding work, due to efficiency increase, saving of electricity and materials.

Innovative Aspect and Main Advantages

The use of the suggested technology allows for complete defects removal, higher mechanical properties of welds, made with fluxes, are not lower than 90 per cent of the basic metal properties.

Scouring fluxes application on fusion welding (TIG, MIG, Laser and Plasma) of aluminum alloys with thickness of plates up to 4 mm gives significant advantages over standard welding techniques, these include:

  • Welding without filler rod (except for 6xxx and 7xxx series alloys);
  • Cuts down on welds’ defects (faulty fusion, oxide inclusions and porosity);
  • Improved weld formation;
  • Protection of welding puddle from environment effects;
  • Improved macro-and-micro structure of welds;
  • Cuts down on requirements for weld surface preparation;
  • Enhanced mechanical properties of welds.

From the cost effectiveness standpoint this technology allows for cut down on welding materials expense (less filler rod and argon are used ), saves on labor involved in weld edge preparation before welding and post-weld quality control inspection of welds.

New activating fluxes for fusion welding of aluminum and it’s alloys, all types of steel, titanium and it’s alloys as well as nickel based alloys in inert gas medium allow to increase productivity of weld constructions by reducing weld size (by increasing penetration), number of welding passes, power and additional materials consumption. For example, the use of activated fluxes saves $15.6 and 65% time at aluminum alloys welding, $19.8 and 62% time at welding of stainless steel and $13.6 and 67% time at welding of carbon and lowalloyed steel in case of 1 working meter of a welded joint.

Areas of Application

The main sector for suggested new technologies and fluxes are companies of such industry branches as rocket building, aircraft and automobile industry, shipbuilding, chemical machine building, nuclear power engineering and others. The main peculiarities of this market sector is that the consumers of the product will be the subdivisions of above mentioned companies, busy with production of welded structures, parts and articles.


Fig. 1 Macrostructure of structural metals and alloys welded joints made by traditional technology and using new fluxes.

Stage of Development

A development worker suggests new fluxes of 12 mark for the mentioned method of welding of aluminum and its alloys, all types of steel, titanium, and its alloys and alloy on the nickel basis. Team of a present project mastered the technology of a piloting production of fluxes in the form of aerosol cans.

Contact Details

Institute of Materials Science
Contact person: Dr. Rustam Saidov
Address: 2B, Mavlyanov St. 100084 Tashkent, Uzbekistan
Tel./Fax: (+998 71) 233 2453
E-mail: This e-mail address is being protected from spambots. You need JavaScript enabled to view it

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