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Development of a Novel Flux-Cored Wire Based on Silicomanganese Gas-Purification Dust


Potentialities have been studied for using flux-cored wire containing industrial wastes (dust taken from the gas-purification facilities of silicomanganese and aluminum production) in order to perform wear-resistant hardfacing. The hardfacing procedure has been carried out using a welding tractor under silicomanganese slag produced by the West Siberian Electrometallurgical Plant. The wear rate of the samples was determined using a 2070 SMT-1 machine. The method for determining wear rate is based on changing in the sample weight during disk-pad testing. The chemical composition of the hardfaced metal layer has been determined using an XRF-1800 X-ray fluorescence spectrometer and using a DFS-71 spectrometer according to atomic emission method. The hardness of the hardfaced layers was measured using a METH-DO hardness tester. The evaluation of the number of nonmetallic inclusions was performed according to GOST (State Standard) 1778–70 using an OLYMPUS GX-51 optical microscope. The manganese uptake coefficient was found at different ratios between components. This coefficient is associated with the reduction of manganese oxide of the manganese-containing flux (due to the carbon contained in the flux-cored wire). In the case of a significant excess of carbon in the flux-cored wire based on manganese-containing flux, the level of manganese uptake exceeds 100%. The process of manganese uptake is determined by the filling coefficient of the flux-cored wire, by the amount of the carbon-containing material in the charge mixture, and by the content of carbon in the arc coating itself. The hardfaced metal layer contains nondeforming silicates and point oxides. The contamination of the hardfaced metal layer by oxide-based nonmetallic inclusions is low. The presence of these nonmetallic inclusions does not affect to any significant extent the operational characteristics of the hardfaced layer.

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Authors ORCID ID. N.A. Kozyrev (0000-0002-7391-6816), A.A. Usol’tsev (0000-0001-6220-7910), L.P. Bashchenko (0000-0003-1878-909X).

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Correspondence to N. A. Kozyrev, R. E. Kryukov, A. A. Usol’tsev, N. V. Kibko or L. P. Bashchenko.

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Translated by O. Polyakov

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Kozyrev, N.A., Kryukov, R.E., Usol’tsev, A.A. et al. Development of a Novel Flux-Cored Wire Based on Silicomanganese Gas-Purification Dust. Steel Transl. 51, 847–852 (2021).

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  • flux-cored wire
  • hardfacing
  • samples
  • nonmetallic inclusions
  • microstructure
  • hardness
  • abrasion rate