Rev. Téc. Ing. Univ. Zulia. Vol. 44, Nº 2, May-August, 2021, 117-126
Rev. Téc. Ing. Univ. Zulia. Vol. 44, No. 2, May-August, 2021.
Relationship between SAW Coatings Composition and The
Composition of Fluxes Obtained with Steel Slag and Rice
Husk Ashes
R. Najarro
1
, A. Cruz-Crespo
2*
, L. Perdomo
2
, A. Duffus
2
, G. Almeida
2
,
M. J. Morales
1
1
Universidad Técnica de Cotopaxi-La Maná, Av. Los Almendros y calle Pujili sector La Virgen,
La Maná - Ecuador.
2
Centro de Investigaciones de Soldadura, Facultad de Ingeniería Mecánica e Industrial,
Universidad Central “Marta Abreu” de Las Villas, CP 54 830, Santa Clara, Cuba.
*Corresponding author: acruz@uclv.edu.cu
https://doi.org/10.22209/rt.v44n2a06
Received: 19 July 2020 | Accepted: 30 March 2021 | Available: 30 April 2021
Abstract
Submerged arc welding (SAW) surfacing is frequently applied on parts that work in abrasive wear
conditions. The applied commercial fluxes are obtained from natural minerals. The objective of this work is to
establish the relationship between the chemical composition of the alloy deposited by SAW and the composition of
the flux, obtained from steel refining slag with the addition of rice husk ashes. Fluxes were obtained by pelletizing,
based on a McLean-Anderson type design. Deposits were obtained with the experimental fluxes, which were
chemically characterized. Empirical models of the element’s composition in the deposited metal as function of the
flux composition were developed, and an optimization process was carried out. It is concluded that the contents of
the elements in the deposited metal show a quadratic dependence, the carbon content (C) is ruled by graphite
composition in the flux, while the chromium (Cr), manganese (Mn) and silicon (Si) contents are ruled by the
FeCrMn content.
Keywords: abrasive wear; hardfacing; SAW fluxes; steel slags.
Vínculo de la Composición de Recubrimientos SAW con la
Composición de Fundentes Obtenidos con Escoria de Acería
y Cenizas de Cascarilla del Arroz
Resumen
El recargue por soldadura con arco sumergido (SAW, según sus siglas en inglés) se aplica con frecuencia en
piezas que trabajan en condiciones de desgaste abrasivo. Los fundentes comerciales que se utilizan son obtenidos a
partir de minerales naturales. El objetivo del presente trabajo fue establecer los vínculos entre la composición
química de la aleación depositada por SAW y la composición del fundente, elaborado a base de escoria de afino del
acero con adición de cenizas de cascarilla del arroz. Se elaboraron fundentes por peletización con base en un diseño
de tipo McLean-Anderson. Con los fundentes experimentales se obtuvieron depósitos, que fueron caracterizados
químicamente. Se obtuvieron modelos de la composición de los elementos en el metal depositado en función de la
composición del fundente y fue realizado un proceso de optimización. Se concluye, que los contenidos de los
elementos en el metal depositado muestran una dependencia cuadrática, siendo el contenido de carbono (C)
gobernado por el de grafito en el fundente, mientras los contenidos de cromo (Cr), manganeso (Mn) y silicio (Si) son
gobernados por el contenido de FeCrMn.
Palabras clave: desgaste abrasivo; escorias de acería; fundente para SAW; recargue duro.
Cruz-Crespo et al . 118
Rev. Téc. Ing. Univ. Zulia. Vol. 44, No. 2, May-August, 2021.
Introduction
Hardfacing by submerged arc welding (SAW) is frequently applied to reduce wear, since it offers a wide
range of possibilities in varying the composition of the deposits and high productivity of the deposition process
(Tusek and Suban, 2003; Gulenç and Kahraman, 2003; Shan-Ping et al., 2004; Mendez et al., 2014).
Almost all SAW fluxes are manufactured from natural minerals. However, the use, of steel welding slags
by SAW, as raw material, is reported (Singh and Pandey et al., 2009). In the aforementioned work, welding slags of
steels by SAW process are used to obtain a new agglomerated flux, also destined for the welding of steel structures.
In previous publications by some of the authors of this work slags of the SiO
2
-MnO system resulting from the SAW
welding of steel structures, and slags of the Al
2
O
3
-MgO-SiO
2
system from obtaining ferrochrome and
ferrochromomanganese, were used as matrix component of a flux for SAW surfacing (Cruz-Crespo et al., 2005;
Cruz-Crespo et al., 2017; Perdomo-González et al., 2017; Cruz-Crespo et al., 2019).
On the other hand, the steelmaking slags are characterized by the majority presence of the CaO-SiO
2
-
MgO-Al
2
O
3
quaternary system. The greatest use of these slags has been focused on civil construction applications.
Slag from the oxidation period during steelmaking, due to their relatively high Fe
2
O
3
and P
2
O
5
contents, are not
viable for the production of fluxes. However, the slags from the steel refining process are suitable as raw material for
the production of SAW fluxes, since these slags practically do not contain Fe
2
O
3
and P
2
O
5
(Najarro-Quintero et al.,
2018a).
Rice husk constitutes an agroindustrial residual to which no systematic treatment has been found, despite
the fact that many authors report the potential of its ashes for its use in the development of new materials, especially
due to its pusollanic properties (Jarre et al., 2021).
In previous studies by the authors of the present work, the use of steel refining slags as a component of the
matrix of a flux for surfacing by SAW was validated, also validating the addition of rice husk ash to incorporate SiO
2
to the matrix system. (Najarro-Quintero et al., 2018a; Najarro-Quintero et al., 2018b). The present work is a
continuity of the referred studies, when considering as objective, to establish the links between the flux composition
variables and the chemical composition of the alloy deposited by SAW, based on a mixtures experimental design for
a restricted region.
Experimental
A McLean-Anderson type experimental design was applied in the study, considered as independent
variables, the flux matrix (X
1
), the graphite (X
2
) and the FeMnCr (X
3
). In flux, graphite and FeCrMn constitute the
alloying system. The experimental matrix (Table 1) was obtained as follows: From the complete design matrix (12
possible combinations of variables), and after applying the normality condition ƩXi = 100 % and eliminating the
points with variables out of range; as well as when considering the coincident experimental points, only 4 valid
experiments remained (a, b, c, d). Between these points, 4 new points were added (ab, bc, cd, da) and one in the
center (abcd).
To obtain each experimental flux the mixture of matrix components was prepared. The composition of the
flux matrix was established in a previous study (Najarro-Quintero et al., 2018a), and its percentage ratio of
components is: 72.99 % slag from the ACINOX Las Tunas ladle furnace, 20.44 % ash from rice husk combustion
and 6.57 % fluorite. The matrix components were brought to a granulometry of less than 0.25 mm; while FeCrMn
and graphite were ground and sieved in a range between 0.1 and 0.25 mm. The compositions of the raw materials
used to obtain the experimental fluxes are shown in Table 2.
The loads of 1 kg, corresponding to each experimental flux (Table 1), were dosed by weighing on a
technical balance. To guarantee the homogeneity of the loads they were mixed in a rotating drum for 30 min.
Agglomeration was carried out by pelletizing, using sodium silicate, as binder, in a proportion of 30 % of the dry
mass. The fluxes obtained were air-dried, then sieved to a particle’s size between 0.25 and 2.0 mm, and finally
calcined in a muffle furnace at 350
o
C for 120 min. The percentage composition of the flux components, considering
the addition of 30 % sodium silicate, is shown in Table 1. The addition of 30 % sodium silicate (SiO
2
- 29.39; Na
2
O-
Relationship between SAW coatings composition and the composition of fluxes 119
Rev. Téc. Ing. Univ. Zulia. Vol. 44, No. 2, May-August, 2021.
10.10 and H
2
O - 60.51 %), provides 11.85 g of (SiO
2
+ Na
2
O) for 100 g of the flux dry mass (matrix + graphite +
FeCrMn), since the water is evaporated during the calcination process, representing 10,59% the contribution of
silicate on the flux (Table 1).
Table 1. Experimental matrix and composition of agglomerated fluxes, % in mass.
Experimental matrix
Agglomerated flux
Experiment
X
1
X
2
X
3
Matrix
FeCrMn
SiO
2
+Na
2
O
a
88
7.0
5.0
78.68
4.47
10.59
b
88
2.0
10.0
78.68
8.94
10.59
c
78
2.0
20.0
69.74
17.88
10.59
d
78
7.0
15.0
69.74
13.41
10.59
ab
88
4.5
7.5
78.68
6.71
10.59
bc
83
2.0
15.0
74.21
13.41
10.59
cd
78
4.5
17.5
69.74
15.65
10.59
da
83
7.0
10.0
74.21
8.94
10.59
acbd
83
4.5
12.5
74.21
11.18
10.59
Table 2. Chemical composition, in mass %, of flux filler components.
Flux matrix components
SiO
2
CaO
CaF
2
CO
2
SO
3
P
2
O
5
Others
Ash, %
90-97
*
-
-
-
-
*
Fluorite, %
2.87
1.12
95.00
0.88
0.10
0.03
-
Flux alloy load components
Cr
Mn
C
Si
S
P
Fe
FeCrMn
19.45
59.02
0.11
2.17
0.0036
0.17
balance
Graphite
-
-
99.00
-
-
-
-
* Variable contents of the oxides of Ca, Mg, K, Na, Al, Fe, etc., depending on the
characteristics of the soils (Cruz, 2009), -: compound or element not present in the raw
material.
Deposits, with experimental fluxes, were made on AISI 1020 steel plates with dimensions 150x80x8 mm.
AWS EL12 electrode wire of 3 mm was used, with a current of 300 A, an arc voltage of 35 V, a welding speed of
43.2 m/h and a flux layer’s height of 20 mm. The deposit was obtained in three superimposed layers. From each
deposit, a sample was extracted for chemical analysis, by cross section cuts in a metallographic cutter. The
composition was determined by atomic emission spectroscopy.
The result processing was carried out with the Statgraphics software, obtaining the regression equations of
C, Cr, Mn and Si contents in the deposited metal, as a function of the input experimental design variables. A
multivariable optimization process was also carried out to define the deposit with the best composition in terms of
abrasive wear.
Results and Discussion
The average chemical composition values of the fundamental elements of the deposits are shown in Table 3.
Equations 1, 2, 3 and 4 reflect the behavior of the C, Cr, Mn and Si contents in the deposited metal, depending on the
flux composition variables. In all cases, the behavior is quadratic, with a high adjustment of the models for C, Cr and
Mn: R
2
= 96.84 % and adjusted R
2
= 91.56 % (p = 0.0186) for C, R
2
= 99.00 % and adjusted R
2
= 97.34 % for Cr (p
= 0.0034), R
2
= 98.33 % and adjusted R
2
= 95.56 % (p = 0.0072) for Mn. The Si model did not show a high
adjustment (R
2
= 89.63 %, adjusted R
2
= 72.35 % and p = 0.1030); however, regularity is observed for a probability
of around 90 %, which makes it possible to evaluate the behavioral trend.
Cruz-Crespo et al . 120
Rev. Téc. Ing. Univ. Zulia. Vol. 44, No. 2, May-August, 2021.
Table 3. Composition of the experimental deposits, contribution of the flux-wire system and transfer coefficients of
the elements to the deposited metal.
Deposits composition (%)
Contribution of the flux-wire
system (%)
Transfer coefficients
Flux
C
Mn
Cr
Si
C
Mn
Cr
Si
K
tC
K
tMn
K
tCr
K
tSi
a
2.53
1.00
0.38
1.26
4.00
1.87
0.56
0.10
0.63
0.54
0.68
12.85
b
0.65
2.87
0.95
1.43
1.17
3.56
1.11
0.16
0.55
0.81
0.85
8.93
c
0.77
4.80
1.34
2.59
1.18
6.93
2.23
0.28
0.65
0.69
0.60
9.11
d
2.83
3.92
1.07
2.29
4.01
5.25
1.67
0.22
0.71
0.75
0.64
10.30
ab
2.01
1.87
0.73
2.36
2.59
2.71
0.83
0.13
0.78
0.69
0.87
18.28
bc
1.00
3.71
1.11
2.11
1.17
5.25
1.67
0.22
0.85
0.71
0.66
9.49
cd
1.73
5.05
1.40
3.06
2.59
6.09
1.95
0.25
0.67
0.83
0.72
12.08
da
2.50
2.33
0.73
2.16
4.00
3.56
1.11
0.16
0.62
0.66
0.66
13.49
abcd
2.09
3.67
1.12
2.33
2.59
4.40
1.39
0.19
0.81
0.83
0.81
12.19
K
tC
, K
tMn
, K
tCr
, K
tSi
: transfer coefficients of C, Mn, Cr and Si, respectively.
C = 0.483333*X
1
+ 0.938333*X
2
+ 0.748333*X
3
+ 8.46*X
1
*X
2
+ 0.99*X
1
*X
3
+ 8.28*X
2
*X
3
, (1)
Cr = 0.672222*X
1
– 3.10278*X
2
+ 1.34722*X
3
+ 4.245*X
1
* X
2
+ 0.075*X
1
*X
3
+ 5.52*X
2
*X
3
, (2)
Mn = 1.66167*X
1
– 7.95583*X
2
+ 4.88917*X
3
+ 10.71*X
1
* X
2
– 0.135*X
1
*X
3
+ 15.3*X
2
*X
3
, (3)
Si = 0.898333*X
1
– 12.7092*X
2
+ 2.54583*X
3
+ 22.86*X
1
* X
2
+ 0.315*X
1
*X
3
+ 21.96*X
2
*X
3
, (4)
The response surfaces (Figures 1, 2, 3 and 4), corresponding to the regression equations (Equations 1, 2, 3
and 4), show the behavior trend. It is observed, as expected, that with the increase of graphite content in the alloying
system of the flux, the C content in the deposited metal tends to increase too. Similarly, the Cr and Mn contents in
the deposits tend to be higher, as the FeCrMn content in the flux increases. In the case of Si, the growth tendency is
governed by the addition of FeCrMn (X
3
), because this component of the flux alloy system directly adds Si, while
Mn acts as a deoxidizer, favoring the SiO
2
reduction.
Figure 1. Isolines of surfaces responses of the C content in the deposit (%), as a function of the matrix (X
1
), graphite
(X
2
) and FeCrMn (X
3
) contents in the flux (%).
Relationship between SAW coatings composition and the composition of fluxes 121
Rev. Téc. Ing. Univ. Zulia. Vol. 44, No. 2, May-August, 2021.
Figure 2. Isolines of response surfaces of the Cr content in the deposit (%), as a function of the matrix (X
1
), graphite
(X
2
) and FeCrMn (X
3
) contents in the flux (%).
Figure 3. Isolines of surface responses of the Mn content in the deposit (%), as a function of the matrix (X
1
),
graphite (X
2
) and FeCrMn (X
3
) contents in the flux (%).
Figure 4. Isolines of surfaces responses of the Si content in the deposit (%), as a function of the matrix (X
1
), graphite
(X
2
) and FeCrMn (X
3
) contents in the flux (%).
Cruz-Crespo et al . 122
Rev. Téc. Ing. Univ. Zulia. Vol. 44, No. 2, May-August, 2021.
The chemical composition described in Table 3, recalculated to 100 % of the Fe-Cr-C ternary system, shows
that in all deposits the primary crystallization of the melting pool occurs with the formation of austenite (Albertin et
al., 2011). Due to the high cooling rates, typical of a welding surfacing process, austenite transforms to martensite.
Cr and Mn, which are carbide formers, shift the isothermal transformation curves of austenite to the right, while
lowering the starting point of the martensitic transformation, which cause the appearance of residual austenite. Given
the chemical composition (Table 3) and the microstructure resulting from cooling, the experimental deposits are
relatively similar to those provided by commercial consumables recommended for abrasive wear (AWS A 5.13,
2014; Kobe, 2007).
Analysis of the deposits alloying process
Table 3 shows the contribution of alloying elements of each flux, in combination with the AWS EL12 wire.
The contribution was determined based on the chemical composition of the alloy load components (Table 2) and
their proportions in the conformation of the experimental fluxes, considering the contribution of sodium silicate, used
as a binder (Table 1). In determining the contribution of elements to the deposit by the flux-wire system, it was
considered that the composition of the AWS EL12 electrode wire is: C-0.09 %; Mn-0.5 %; Si-0.1 % (AWS A 5.17,
2001) and that the flux/wire consumption ratio is around 1.8 (of the total consumption, the flux represents 64 % and
the wire 36 %).
When comparing the contributions of the flux-wire system with the composition of the experimentally
deposited metal (Table 3 and Figure 5), it is observed that there is relative correspondence for Cr, Mn and C. The
contribution of the wire-flux system differs of the composition of deposits, since oxidation-reduction processes take
place during deposition. The tendency to a certain linearity in the behavior between the contribution of the flux-wire
system and the experimental composition obtained in the deposits (Figure 5), shows that the concentration conditions
govern the metal alloying, despite the high cooling rates that take place in SAW surfacing, which can lead the system
to thermodynamic inbalance.
The Si contents in the experimental deposits significantly exceed the values of this element provided by the
flux-wire system (Table 3). This is caused by the silica reduction (Equation 5) in the high temperature zones (in the
drop and the front zone of the weld pool). The [FeO] dissolved in the liquid metal reacts with the [Mn] and [C],
contained in the pool, according to the reactions of Equations 6 and 7, releasing iron and favoring the reduction of
SiO
2
at the metal-slag interface by Equation 5 (Quintana et al., 2003). The high SiO
2
content in the weld slag,
provided by the flux matrix (SiO
2
is provided by the steel slag, by the ash and by the sodium silicate), and the
presence of Mn and C that act as deoxidizers (Equations 6 and 7), favor the reaction of Equation 5, which leads to
the increase of this element in the metal. Namely:
][2][)(2
2
FeOSiSiOFe
(5)
FeMnOFeOMn )(][][
(6)
FeCOFeOC ][][
(7)
Based on the content of elements provided by the flux-wire system and the composition of the deposits
obtained experimentally, the transfer coefficients of the elements were determined (K
tE
= E
exp
/E
theoretical
; K
tE
- transfer
coefficient of the element to the deposited metal, E
exp
and E
theoretical
- experimental and theoretical contents of the
element in the deposited metal) (Table 3). The transfer coefficient reflects the effective use of the alloying element,
provided by the consumables to obtain the deposited metal. In the case of C, Mn and Cr, since the values are lower
than one, it is confirmed that there are losses related to the oxidation of these elements. The C and Mn transfer
coefficient values, in a general exceed those frequently reported in the literature; while Cr transfer coefficient is in
the range reported by literature, with only two values higher than said range (Potapov, 1989; Quintana et al., 2003).
In the case of Si, in correspondence with what has already been discussed about the reduction of SiO
2
, the transfer
Relationship between SAW coatings composition and the composition of fluxes 123
Rev. Téc. Ing. Univ. Zulia. Vol. 44, No. 2, May-August, 2021.
coefficient is significantly higher than one, evidencing that there has been incorporation of this element into the
deposit, after a reductive process of the oxide from the slag, according to Equation 5.
Figure 5. Relationship between the contents of the alloying elements in the flux-wire system and in the
deposited metal.
The similar trend behavior of the Cr and Mn contents in the deposited metal (Figures 2 and 3), being these
elements added by the same load component of the flux (FeCrMn, identified as the variable X
3
in the experimental
plan, Table 1), shows that the deposit alloying is governed by the concentration conditions.
In the case of C, due to the relatively low amount of atmospheric oxygen and the high temperatures in the
arc, its oxidation occurs predominantly with the oxides in the liquid metal (Quintana et al., 2003).
Flux composition optimization
As already stated, all the deposits obtained with the experimental fluxes in combination with AWS EL12
wire (Table 3), could satisfy the requirements for abrasive wear. However, from the point of view of the deposited
metal composition, the C and Cr contents should be the highest possible, since this favors the formation of hard
structures that limit the penetration of the abrasive material on the coating surface. The independent optimization of
these two responses (C and Cr in the deposited metal), through processing with the Statgraphics software, provides
the following: C
opt
= 2.7 % (X
1
= 81.45; X
2
= 7.0 and X
3
= 11.55%); C
ropt
= 1.4 % (X
1
= 78.0; X
2
= 3.45 and X
3
=
18.55 %). The foregoing shows that the best results of the C and Cr content in the deposit are not coincident, in terms
of composition of the flux, so it is necessary to find a compromise condition, which can be achieved by obtaining the
function of desirability (Becerra et al., 2014).
Multivariable optimization processing was done, maximizing C and Cr as responses. As a result, the graph
of the “desired” function has been obtained (Figure 6). It is observed that the best results tend towards an increase in
graphite and a decrease in the matrix with high FeCrMn values, the optimum of the “desired” function being equal to
0.82, which corresponds to the following: C
opt
= 2.45 and Cr
opt
= 1.22 % (X
1
= 78.0; X
2
= 6.12 and X
3
= 15.88 %).
This optimum coincides with the experimental point "d" (Table 1). Due to its composition, this deposit could satisfy
the requirements for abrasive wear, corresponding to the AWS EFe5 classification, according to what was reported
Cruz-Crespo et al . 124
Rev. Téc. Ing. Univ. Zulia. Vol. 44, No. 2, May-August, 2021.
for welding surfacing consumables (AWS A 5.13, 2010). The Mn in the deposit contributes to the presence of
residual austenite, which is favorable under abrasion with impact conditions.
Figure 6. Behavior of the "desired" function, depending on the matrix (X1), graphite (X
2
) and FeCrMn (X3) contents
in the flux (%).
The hardness of the deposit obtained with the flux "d" (549 HV, 53 HRc) and the microstructure shown in
Figure 7, with the presence of needle-shaped martensite and residual austenite, indicate that the flux selected as
optimal, could be suitable for abrasive wear. Several authors, among which are Gulenc and Kahraman (2003), and
Coronado et al. (2009), carried out studies that validate the performance on abrasive wear of steels coatings, with a
similar composition and microstructure of the deposits in the present work.
Figure 7. Microstructure of deposit “d” obtained by optical microscopy (needle-shaped martencite-dark area and
austenite-light area).
Relationship between SAW coatings composition and the composition of fluxes 125
Rev. Téc. Ing. Univ. Zulia. Vol. 44, No. 2, May-August, 2021.
Conclusions
It is confirmed that slags from the steel refining process, with rice husk ashes as an additive, are viable to
use as matrix components of alloyed agglomerated fluxes for surfacing by SAW process.
The C, Cr, Mn and Si contents in the deposited metal, as a function of the matrix, graphite and FeCrMn
contents in the fluxes, show a quadratic dependence. The graphite content in the flux governs the C content in the
deposits, while the Cr, Mn and Si content are governed by the FeCrMn content in the flux. The transfer of C, Cr and
Mn to the deposit, from the flux-wire system, is manifested with losses due to the oxidation processes of these
elements, while the Si content in the deposited metal is higher than that provided, due to the reduction of SiO
2
present in the slag.
The compositions of the deposits obtained with the experimental fluxes are in similar ranges to those of
commercial consumables for abrasive wear, characterized by the predominance of martensite in the microstructure
and the presence of residual austenite. From the optimization process to maximize C and Cr, the flux with the best
properties is similar to the experimental "d" and is characterized by C
opt
= 2.45 and Cr
opt
= 1.22 % (X
1
= 78.0; X
2
=
6.12 and X
3
= 15.88 %), with hardness around 53 HRc.
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