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<p>This work investigates the effect of flux composition on the chemical and mechanical properties of multipass weld deposits produced using SS309L core wires. Twenty-one flux formulations were prepared by varying the proportions of CaO, SrO, Al₂O₃, and CaF₂. The results show that flux composition significantly affects alloying element retention and weld metal hardness. Chromium retention increased with increasing Al₂O₃ content, while higher levels of CaO, CaF₂, and SrO led to greater chromium loss, attributed to enhanced slag–metal reactions during welding. Nickel and manganese transfer depended on both individual flux constituents and their binary and ternary interactions, indicating non-linear transfer behavior. Iron content generally increased with individual additions of the four components but decreased for certain combined compositions. These changes in weld metal chemistry were reflected in the measured microhardness, which ranged from 159.47 HV to 194.68 HV and was associated with carbide and intermetallic phase formation during solidification. Among the predictive methods evaluated, artificial neural networks showed better agreement with experimental results, while regression analysis was useful for identifying the effects of individual flux components. The results confirm that flux composition is an important factor in controlling weld metal chemistry and hardness in SMAW consumables.</p>

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Experimental and ANN-based study on the role of flux components in alloying element retention during SMAW

  • 期刊论文

  • 发表日期：

    2026年3月19日

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  • Alok Gupta,
  • Jaiveer Singh,
  • Rahul Chhibber,
  • Yogesh Kumar Singla

摘要

This work investigates the effect of flux composition on the chemical and mechanical properties of multipass weld deposits produced using SS309L core wires. Twenty-one flux formulations were prepared by varying the proportions of CaO, SrO, Al₂O₃, and CaF₂. The results show that flux composition significantly affects alloying element retention and weld metal hardness. Chromium retention increased with increasing Al₂O₃ content, while higher levels of CaO, CaF₂, and SrO led to greater chromium loss, attributed to enhanced slag–metal reactions during welding. Nickel and manganese transfer depended on both individual flux constituents and their binary and ternary interactions, indicating non-linear transfer behavior. Iron content generally increased with individual additions of the four components but decreased for certain combined compositions. These changes in weld metal chemistry were reflected in the measured microhardness, which ranged from 159.47 HV to 194.68 HV and was associated with carbide and intermetallic phase formation during solidification. Among the predictive methods evaluated, artificial neural networks showed better agreement with experimental results, while regression analysis was useful for identifying the effects of individual flux components. The results confirm that flux composition is an important factor in controlling weld metal chemistry and hardness in SMAW consumables.