Abstract

Offshore structures in recent time are witnessing the increased application of dissimilar metal welds for enhanced structural integrity. Offshore structures are complex systems. Fabrication, maintenance, and repair of these structures require conventional and advanced welding technologies along with suitably chosen welding consumables. The present work aims at the design and development of shielded metal arc welding (SMAW) electrode coating using extreme vertices design methodology. This work also attempts to study weld metal chemistry along with microstructure and microhardness. Red ochre, a mineral waste from iron ore is added in the coating composition. Multi response optimization has been carried out to obtain optimum flux composition and to study the effect of individual constituents and their interactions on the weld chemistry and microhardness.

References

1.
Belkessa
,
B.
,
Miroud
,
D.
,
Ouali
,
N.
, and
Cheniti
,
B.
,
2016
, “
Microstructure and Mechanical Behavior in Dissimilar SAF 2205/API X52 Welded Pipes
,”
Acta Metall. Sin (Eng. Lett.)
,
29
(
7
), pp.
674
682
.10.1007/s40195-016-0428-8
2.
Sadeghian
,
M.
,
Shamanian
,
M.
, and
Shafyei
,
A.
,
2014
, “
Effect of Heat Input on Microstructure and Mechanical Properties on Dissimilar Joints Between Super Duplex Stainless Steel and High Strength Low Alloy Steel
,”
Mater. Des.
,
60
, pp.
678
684
.10.1016/j.matdes.2014.03.057
3.
Rathod
,
D. W.
,
Pandey
,
S.
,
Singh
,
P. K.
, and
Prasad
,
R.
,
2015
, “
Experimental Analysis of Dissimilar Metal Weld Joint: Ferritic to Austenitic Stainless Steel
,”
Mater. Sci. Eng. A
,
639
, pp.
259
268
.10.1016/j.msea.2015.05.011
4.
Chhibber
,
R.
,
Arora
,
N.
,
Gupta
,
S. R.
, and
Dutta
,
B. K.
,
2006
, “
Use of Bimetallic Welds in Nuclear Reactors: Associated Problems and Structural Integrity Assessment Issues
,”
Proc. Inst. Mech. Eng. Part C: J. Mech. Eng. Sci
,
220
(
8
), pp.
1121
1133
.10.1243/09544062JMES135
5.
Bhandari
,
D.
,
Chhibber
,
R.
,
Arora
,
N.
, and
Mehta
,
R.
,
2016
, “
TiO2–SiO2–CaO–CaF2 Based Electrode Coatings on Weld Metal Chemistry and Mechanical Behavior of Bimetallic Welds
,”
J. Manuf. Process.
,
23
, pp.
61
74
.10.1016/j.jmapro.2016.05.013
6.
Hazlett
,
T. H.
,
1957
, “
Coating Ingredients Influence on Surface Tension, Arc Stability and Bead Shape
,”
Weld J.
,
36
(
1
), pp.
18
22
.
7.
Sharma
,
L.
, and
Chhibber
,
R.
,
2019
, “
Design of TiO2-SiO2-MgO and SiO2-MgO-Al2O3 Based Submerged Arc Fluxes for Multipass Bead on Plate Pipeline Steel Welds
,” ASME
J. Pressure Vessel Technol.
,
141
, p.
041402
.10.1115/1.4043375
8.
Sharma
,
L.
, and
Chhibber
,
R.
,
2019
, “
Design of CaO–SiO2–CaF2 and Cao–SiO2–Al2O3 Based Submerged Arc Fluxes for Series of Beads on Plate Pipeline Steel Welds—Effect of Carbon and Manganese Content, Grain Size and Micro Hardness
,” ASME
J. Pressure Vessel Technol.
,
141
, p.
031403
.10.1115/1.4043298
9.
Kanjilal
,
P.
,
Majumdar
,
S. K.
, and
Pal
,
T. K.
,
2004
, “
Prediction of Submerged Arc Weld-Metal Composition From Flux Ingredients With the Help of Statistical Design of Mixture Experiment
,”
Scand. J. Metall.
,
33
(
3
), pp.
146
159
.10.1111/j.1600-0692.2004.00679.x
10.
Franks
,
D. M.
,
Boger
,
D. V.
,
Cote
,
C. M.
, and
Mulligan
,
D. R.
,
2011
, “
Sustainable Development Principles for the Disposal of Mining and Mineral Processing Wastes
,”
Resour. Policy
,
36
(
2
), pp.
114
122
.10.1016/j.resourpol.2010.12.001
11.
Taha
,
Y.
,
Benzaazoua
,
M.
,
Hakkou
,
R.
, and
Mansori
,
M.
,
2016
, “
Natural Clay Substitution by Calamine Processing Wastes to Manufacture Fired Bricks
,”
J. Cleaner Prod.
,
135
, pp.
847
858
.10.1016/j.jclepro.2016.06.200
12.
Garu
,
S.
,
Amritphale
,
S. S.
,
Mishra
,
J.
, and
Joshi
,
S.
,
2019
, “
Multicomponent Red Mud Polyster Composites for Neutron Shielding Applications
,”
Mater. Chem. Phys.
,
224
, pp.
369
375
.10.1016/j.matchemphys.2018.12.039
13.
Vigneshwaran
,
S.
,
Uthayakumar
,
M.
, and
Arumugaprabu
,
V.
,
2019
, “
Development and Sustainability of Industrial Waste Based Red Mud Hybrid Composites
,”
J. Cleaner Prod.
,
230
, pp.
862
868
.10.1016/j.jclepro.2019.05.131
14.
Li
,
Y.
,
Min
,
X.
,
Ke
,
Y.
,
Liu
,
D.
, and
Tang
,
C.
,
2019
, “
Preparation of Red Mud Based Geopolymer Materials From MSWI Fly Ash and Red Mud by Mechanical Activation
,”
Waste Manage.
,
83
, pp.
202
208
.10.1016/j.wasman.2018.11.019
15.
Ambroza
,
P.
, and
Kavaliauskiene
,
L.
,
2008
, “
Utilisation of Waste Material for Welding and Surfacing
,”
Mechanika
,
70
(
2
), pp.
56
60
.10.5755/j01.mech.70.2.14938
16.
Mukiza
,
E.
,
Zhang
,
L.
,
Liu
,
X.
, and
Zhang
,
N.
,
2019
, “
Utilization of Red Mud in Road Base and Subgrade Materials: A Review
,”
Resour. Conserv. Recycling
,
141
, pp.
187
199
.10.1016/j.resconrec.2018.10.031
17.
Anderson
,
V. L.
, and
McLean
,
R. A.
,
1974
,
Design of Experiments: A Realistic Approach
,
Marcell Dekker
,
New York
.
18.
Jindal
,
S.
,
Chhibber
,
R.
, and
Mehta
,
N. P.
,
2013
, “
Investigation on Flux Design for Submerged Arc Welding of High-Strength Low-Alloy Steel
,”
J. Eng. Manuf.
,
227
(
3
), pp.
383
395
.10.1177/0954405412468993
19.
Shwemmer
,
D. D.
,
Olson
,
D. L.
, and
Williamson
,
D. L.
,
1979
, “
The Relationship of Weld Penetration to the Welding Flux
,”
Weld. J.
,
5
, pp.
153 s
160 s
.https://app.aws.org/wj/supplement/WJ_1979_05_s153.pdf
20.
Mitra
,
U.
, and
Eagar
,
T. W.
,
1984
, “
Slag Metal Reactions During Submerged Arc Welding of Alloy Steels
,”
Metall. Trans. A
,
15
(
1
), pp.
217
227
.
21.
Bhandari
,
D.
,
Chhibber
,
R.
,
Arora
,
N.
, and
Mehta
,
R.
,
2016
, “
Investigation on Weld Metal Chemistry and Mechanical Behavior of Bimetallic Welds Using CaO–CaF2–SiO2–Ni Based Electrode Coatings
,”
Proc. IMechE Part L: J Mater. Des. Appl.
,
233
(
4
), pp.
563
579
.10.1177/1464420716677316
You do not currently have access to this content.