The National Shipbuilding Research Program, Development and Evaluation of Improved Flux-Cored Welding Consumables, Phase 1
NAVAL SURFACE WARFARE CENTER CARDEROCK DIV BETHESDA MD
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The objective of NSRP Project 7-95-4 is to evaluate and develop an improved flux-cored wire for use in commercial shipbuilding that can be produced within the U.S. and is comparable or exceeds those available from foreign producers. This report deals with a portion of the first phase consisting of evaluating FCAW wires from U.S. and foreign manufacturers to identify the differences in weldability, arc characteristics and quality. The electrode evaluation consisted of a semiautomatic mechanized portion and an automatic robotic portion. The semiautomatic mechanized portion consisted of welding both fillet and butt joints, evaluating feedability, operability, slag removability and smokefume generation. The automatic robotic portion consisted of welding fillet joints and evaluating operability, seam tracking, parameter variation, depth of weld root penetration, travel speed and multipass fillet welding over slag. Overall there was no significant performance advantage of foreign wires over the domestic wires tested. However, there were differences attributed to the various shielding gases. For semiautomatic mechanized welding, 75 Ar - 25 CO2 wire had the best operability, mainly in out-of-position welding. For automatic welding, 100 CO2 wires provided the best travel speed and penetration with comparable operability. All wires deposited sound multipass fillet welds over slag.
- Properties of Metals and Alloys
- Marine Engineering