1 UNIONMELT® Submerged Arc Fluxes Spoolarc® Solid Wires and ALLOY SHIELD® Composite Wires The major function of a submerged arc welding flux is to: n Shield the molten puddle from the atmosphere. n Clean and deoxidize the weld puddle. n Control the chemistry and mechanical properties of the weld metal. There are two major methods by which fluxes are manufactured: BONDED FLUXES are manufactured by dry mixing the flux ingredients and then bonding them together using a liquid silicate binder. The flux pellets are then baked at a relatively low temperature to drive off the water in the binder. The major advantages of bonded fluxes are: n The flux can contain metallic deoxidizers which provide good performance over rust and mill scale. n The relatively coarse mesh size feeds easily due to its uniform size. n Bonded fluxes typically have a lower consumption rate. The use of bonded fluxes are not without limitation. They include: n Any removal of undersized particles during recycling can change the overall chemical analysis of a bonded flux and consequently, change the performance characteristics of the flux. n Segregation within the flux can occur, making some particles richer or leaner in specific ingredients. This is particularly critical if metals segregate, leading to hard spot formation within the weld metal. n Bonded fluxes can pick up moisture if stored improperly. They must be baked at a temperature between 500°-800°F (260°-427°C) to remove any suspected moisture. Continued on next page...
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