Ceramic flux
The composition of the weld metal affects its structure and resistance to crack formation. The composition of the gas atmosphere determines the stability of the arc burning, resistance to the formation of pores, and the amount of harmful gases released during welding.
Fluxes perform the following functions: physical isolation of the welding pool from the atmosphere, stabilization of the arc discharge, chemical interaction with the liquid metal, alloying of the weld metal, and formation of the weld surface. The best insulating ability is found in fluxes with a dense structure of fine granulation particles.
However, with a dense packing of flux particles, the formation of the weld surface may deteriorate. Sufficiently effective protection of the welding pool from atmospheric effects is provided at a certain thickness of the flux layer.
Fluxes perform the following functions:
- Physical isolation of the welding pool from the atmosphere;
- Stabilization of the arc discharge;
- Chemical interaction with the liquid metal;
- Alloying of the weld metal;
- Formation of the weld surface.
Advantages of Ceramic Flux over Melted Flux
- The average consumption of ceramic flux is generally 40% lower than that of melted flux.
- The use of ceramic flux in recirculation systems ensures its flawless delivery to the welding zone compared to its melted counterpart.
- The possibility of multiple uses of ceramic fluxes is a significant advantage in the production process.
- The formation of the weld bead is better when using ceramic fluxes, resulting in a neater weld bead.
- Ceramic flux is an environmentally friendly product compared to melted flux.
- There is no fume generation at the welder's workspace during welding with ceramic flux.
- When welding with ceramic fluxes, alloying of the weld metal is possible, whereas alloying is difficult with melted fluxes.
- Ceramic fluxes allow for welding with lower specific energy, which improves the characteristics of the welded joint.