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Dilution in single pass arc welds

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Abstract

A study was conducted on dilution of single pass arc welds of type 308 stainless steel filler metal deposited onto A36 carbon steel by the plasma arc welding (PAW), gas tungsten arc welding (GTAW), gas metal arc welding (GMAW), and submerged are welding (SAW) processes. Knowledge of the arc and melting efficiency was used in a simple energy balance to develop an expression for dilution as a function of welding variables and thermophysical properties of the filler metal and substrate. Comparison of calculated and experimentally determined dilution values shows the approach provides reasonable predictions of dilution when the melting efficiency can be accurately predicted. The conditions under which such accuracy is obtained are discussed. A diagram is developed from the dilution equation which readily reveals the effect of processing parameters on dilution to aid in parameter optimization.

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Abbreviations

A:

constant in Eq. [5]

A fm :

cross-sectional area of deposited filler metal

A s :

cross-sectional area of melted substrate

B:

constant in Eq. [5]

C p :

specific heat

D:

dilution

d:

width of weld

E:

melting enthalpy

E fm :

melting enthalpy of filler metal

E s :

melting enthalpy of substrate

ΔH f :

latent heat of fusion

I:

welding current

S:

travel speed of heat source

V:

voltage

V fm :

volumetric filler metal feed rate

V s :

volumetric melting rate of substrate

ν fm :

melted tiller metal volume

ν s :

melted substrate volume

α:

thermal diffusivity

η a :

arc efficiency

η m :

melting efficiency

γ:

dilution parameter = (1/D) - 1

ν:

kinematic viscosity at the melting point

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Authors and Affiliations

  1. Department of Materials Science and Engineering, Lehigh University, 18015, Bethlehem, PA

    J. N. DuPont (Associate Research Scientist) & A. R. Marder (Professor)

Authors
  1. J. N. DuPont
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  2. A. R. Marder
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DuPont, J.N., Marder, A.R. Dilution in single pass arc welds. Metall Mater Trans B 27, 481–489 (1996). https://doi.org/10.1007/BF02914913

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