Droplet Transition and Corrosion Resistance of Surfacing Layer with Flux-Core and Solid Twin-Wire Indirect Arc Welding

In this study, the utilization of flux-cored and solid wires is investigated in the bypass-coupling of twin-wire indirect arc welding for surfacing applications. Simultaneously recording arc burning, droplet transition, and current voltage enabled the comparison of droplet transition behavior under various welding currents and cathode wire feeding speeds. Additionally, an exploration into the voltage and current characteristics of both indirect and direct arcs was conducted. Furthermore, an analysis of the microstructure and corrosion resistance of the surfacing layers was undertaken. At a welding current ranging from 180 to 200 A, with a cathode wire feeding speed of approximately 415 cm/min, the droplet transition exhibited relative stability. As the flux-cored wire droplet expanded, the indirect arc current diminished, while the direct arc current escalated. With an increase in welding current, weld penetration and width gradually augmented, accompanied by a reduction in weld reinforcement. Additionally, the corrosion resistance of the surfacing layer deteriorated. Taking into account the overall stability of the welding process, as well as the formation and corrosion resistance of the surfacing layer, it was observed that at a welding current of 180A, a surfacing layer exhibiting commendable corrosion resistance could be efficiently and reliably attained.