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Journal of Emerging Trends in Engineering and Applied Sciences (JETEAS)


Article Title: Formulation of a Metal Arc Welding Flux with a Potash Enriched Sodium Silicate Binder
by Nwigbo Solomon Chukwuka, Atuanya C.U

A new flux for metal arc welding has been developed. The basic components fall under the category of the rutile electrode. These include: titanium (iv) oxide, iron powder, Cellulose, sodium silicate binder and other additives. In this work, one of the major components was technically and economically substituted. The more popular but expensive potassium silicate binder was replaced by the more readily available sodium silicate. For the newly chosen binder to perform effectively, it was enriched with potassium carbonate (Potash). The flux formulation was not based on the old method of trial and error but some mathematical methods, especially the experimental design approach were applied. The Mc-Cleans and Anderson method was used in the preliminary design to generate the orthogonal array that guided the formulation. Four major components: Titanium dioxide, Iron powder, cellulose and Sodium silicate binder enriched with Potash were considered as the major contributing elements. An electrode made out of the flux was used by some professional welders and their comment on the quality of the electrode was impressive. Tests on the sample of the weldment showed that it could withstand a tensile strength up to 430 N/mm2. The Brinell's harness value gave a maximum of 608 N/mm2. Also, the Nick Break revealed a good penetration, no slag inclusion. The micrograph presented an acceptable grain structure.
Keywords: flux, potash, experimental design, sodium silicate, binder
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ISSN: 2141-7016

Editor in Chief.

Prof. Gui Yun Tian
Professor of Sensor Technologies
School of Electrical, Electronic and Computer Engineering
University of Newcastle
United Kingdom



Copyright © Journal of Emerging Trends in Engineering and Applied Sciences 2010