Discussion on Performance Evaluation Method of Welding Process for Welding Rods for Engineering Applications
1. Overview
China has emerged as the world's largest producer of welding materials, yet the share of high-end and specialized welding consumables remains relatively low. For instance, in the field of nuclear power welding materials, China has been developing welding solutions for nuclear island main equipment since the 1970s, achieving numerous technological breakthroughs. However, despite these efforts, a significant portion of welding materials used in nuclear power plants are still imported. This is not only due to metallurgical limitations but also because the quality and stability of domestic products often fall short compared to their imported counterparts. The inconsistency in performance and the lack of standardized, quantifiable criteria have become major barriers to the widespread adoption of high-quality welding materials in the nuclear industry.
This paper takes the electrode as a case study, examining how the key components of welding performance affect real-world applications. It also reviews current methods for evaluating electrode performance and proposes an engineering-oriented approach that incorporates on-site welder feedback and quantitative testing. By establishing clear technical standards and performance indicators, this research aims to improve the overall welding process performance of domestic welding materials.
2. Analysis of Welding Process Performance Impact
The welding process performance of electrodes includes several critical factors such as arc stability, slag removal, re-ignition capability, spatter rate, melting coefficient, deposition efficiency, dust generation, and weld appearance quality. Among these, arc stability plays a central role in determining the effectiveness of the welding process in engineering applications.
Arc stability refers to the ability of the electrode to maintain a consistent and continuous arc during welding. It directly affects the usability of the electrode and the progress of construction. For example, in the case of alkaline stainless steel electrodes, large droplet transfer can lead to longer short-circuit times, increasing the risk of arc extinction. On the other hand, fine droplet transfer through the slag wall results in a more stable welding process.
Slag removal refers to how easily the weld slag covering the weld bead can be removed after welding. The mechanism behind this is often explained by the "combination layer theory" between the slag and the weld metal. A FeO film forms on the surface, matching the crystal structure of the base metal and the slag components, making it difficult to remove the slag. This leads to time-consuming and labor-intensive cleaning processes, which reduce productivity and increase the risk of defects and poor joint performance.
Welding spatter refers to metal particles that fly out of the molten pool during the droplet transfer and remain on the weld or nearby areas after cooling. In alkaline stainless steel electrodes, different slag systems result in varying spatter behaviors, including splashing from short-circuit transitions or arc force. The size and frequency of these particles can significantly impact the quality of the weld, especially in pipe welding where uncontrolled spatter may stick to the groove or previous beads, increasing cleaning work and the likelihood of defects.
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