International Journal of Mechanical Engineering and Technology (IJMET)

Volume 9, Issue 6, June 2018, pp. 450–458, Article ID: IJMET_09_06_051

Available online at http://www.iaeme.com/ijmet/issues.asp?JType=IJMET&VType=9&IType=6
ISSN Print: 0976-6340 and ISSN Online: 0976-6359

© IAEME Publication Scopus Indexed

A STUDY OF PFTIG AND FBTIG WELDING

PROCESS ON BEAD MORPHOLOGY USING
NANOPARTICLES ON 15CDV6 STEEL
Skariya P D
Department of Mechanical Engineering, NICHE, Nagercoil, India

Satheesh M
Department of Mechanical Engineering, NICHE, Nagercoil, India

Edwin Raja Dhas

Department of Automobile Engineering, NICHE, Nagercoil, India

Suneesh E
Department of Production Engineering, VAST, Kerala, India

ABSTRACT
This research work attempted a study regarding the effect of different
nanoparticles on PFTIG (Powdered flux Tungsten inert gas) welding of 15CDV6 steel.
The Nanopowders used for this work are TiO2, SiO2, Cr203, ZnO, and NiO. The
analysis of bead morphology is conducted by using these nanoparticles and observed
that all Nanopowders provide a better penetration except Cr203 flux. The TiO2 flux
shows the maximum penetration compared to other fluxes and is evident from the
macrostructure of the weldments. The measurement of arc voltage and arc divergent
angles indicates that the phenomenon of arc constriction was strongly present while
using TiO2 and SiO2 Nano fluxes. The constriction of arc provides deeper penetration
and a higher aspect ratio compared to conventional TIG welding and other Nano
fluxes. A variant of PFTIG welding process known as FBTIG is incorporated in this
study using TiO2 flux and it shows a positive effect on bead morphology. The FBTIG
bead on plate trials is conducted by using various flux gaps, and full penetration is
achieved while using 3mm flux gap.
Keywords: PFTIG Welding, 15CDV6 Steel, FBTIG Welding, bead morphology,
Nano flux
Cite this Article: Skariya P D, Satheesh M, Edwin Raja Dhas and Suneesh E, A
Study of Pftig and Fbtig Welding Process on Bead Morphology Using Nanoparticles
on 15cdv6 Steel, International Journal of Mechanical Engineering and Technology,
9(6), 2018, pp. 450–458
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 A Study of Pftig and Fbtig Welding Process on Bead Morphology Using Nanoparticles on
15cdv6 Steel

1. INTRODUCTION
The HSLA are high strength low alloy steels, and generally, they are low carbon steels. The
total weight of the alloying elements in HSLA steel should be less than 5%, and yield strength
ranges in between 275 to 590 Mpa. 15CDV6 is an HSLA steel, and the carbon percentage is
0.15 [1]. The designation of this steel is French and C for chromium, D for molybdenum and
V for vanadium [2]. The steel is popular for the fabrication of rocket motor casings, formula
car applications etc. [3]. Gas Tungsten arc welding is considered as the popular process for
the fabrication of High strength low alloy steels because it provides a defect-free weld [4].
The fabrication process of this steel is completed with the help of multiple passes and filler
wire [5]. The non-uniformity of residual stresses and angular distortions are the major
disadvantages behind multiple pass welding, and it will lead to cracking tendency of
weldments due to tensile residual stresses [6]. This problem can be tackled with the assistance
of powdered flux TIG welding or PFTIG using nanopowders. The PFTIG welding process is
a single pass autogenous welding and can lead to the uniformity of residual stresses and
cracking tendency can reduce to a larger extent. The remarkable advantage of PFTIG welding
is its desired bead morphology and can increase the productivity compared to conventional
GTA welding [7]. The work is conducted using nanopowders because of its smaller particle
size and very low thermal stability while comparing with powders having a micro size [8].
In FBTIG or flux bounded Tungsten inert gas welding process, a flux gap is maintained in
the middle of the weld and flux coating is applied on either side of the flux gap [9]. The flux
gap provides a channel for the electrons to flow through the thickness since the flux acts as an
insulating layer in welding [10]. The free flow of electrons generates the arc, and it melts the
metal and hence providing a deeper penetration. The highly intensified arc decomposes the
flux, and the surface active elements present in the nano flux promotes the reversal of
Marangoni flow, and optimum bead morphology is obtained with the use of FBTIG welding
[11]. G Chandrasekar et al., [12] conducted a study using TiO2 and SiO2 fluxes and found that
50% proportion of these two fluxes procures a better bead morphology and mechanical
properties on AISI 316L austenitic stainless steel. S Jayakrishnan et al., [13] reported that
silica flux coating has low particle size and low thermal stability provides an optimum bead
morphology such as penetration and depth to width ratio compared to a coating having more
particle size and thermal stability. Akhilesh Kumar Singh et al., [14] observed that FBTIG
welding with ceramic flux increases the penetration two to three times compared to
conventional GTA welding. Xiong Xie et al., [15] reported that TIG welding with the
assistance of nanopowders provides sound bead geometry because of its significant
dissociation and the peak temperatures generated from the PFTIG welding process.
It has been found out that there is no work conducted so far regarding the development of
optimum Nano flux and flux gap using PFTIG and FBTIG welding of 15CDV6 HSLA steels.
The effect of various nanopowders and conventional GTA welding on the bead dimensions of
low alloy steel welds and the oxygen concentration in all the normal and Nano coated welds
studied to investigate the phenomena behind the optimum bead morphology. The
requirements of a sound weld are also assessed by evaluating the width and depth of FBTIG
weldments for checking the possibility of cracking tendency and other defects in the
weldments. This research is beneficial to the various sectors that have been exploiting
15CDV6 steel.

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 Skariya P D, Satheesh M, Edwin Raja Dhas and Suneesh E

2. EXPERIMENTAL DETAILS
The 15CDV6 steel plates were procured from LPSC, Thiruvananthapuram, Kerala. The plates
were sectioned into 100mm x 100mm x 6.2mm strips. The chemical analysis 15CDV6 steel is
conducted using Atomic emission spectroscopy and shown in table 1. The single-pass TIG
welding is used to make the bead-on-plate welds with an autogenous setup. The process
parameters are listed in table 2, and autogenous welding setup in a single pass is conducted
for making a bead on alloy plate. Five Nanoparticle powders, i.e., TiO2, SiO2, Cr203, ZnO, and
NiO are used for this research. The nano oxides utilised in this study are having low thermal
stability and decompose at higher welding temperatures than other oxides. The oxide fluxes
were purchased from Ultra Nano labs, Haryana having 40-60 nm particle size. The methanol
is added to these nanoparticles to form a paste.

Table 1 Chemical analysis of 15CDV6 steel

Element C Cr Mn Mo Ni V Si Cu P
Weight % 0.152 1.229 0.838 0.791 0.234 0.198 0.189 0.107 0.005

Table 2 Parameters for bead on plate trials

Polarity DCEN
Welding current 189 Amperes
Travel speed 73 mm/min
Arc gap 1.5 mm
Torch angle 110 degree
Gas flow rate 8 ltr/min
Diameter of electrode 3.2 mm

Table 3 Physical properties of nanopowders

Molecular Specific Molar Melting
IUPAC name of Density ρ Cost
formula of surafce area mass M temperature
Nanopowder (gm/cm3) (Rs/gm)
flux (m2/gm) (gm/mol) (0C)
Titanium (IV) oxide TiO2 4.23 204-220 79.87 1843 160
Silicon dioxide SiO2 2.65 200-600 60.08 1710 132
Chromium(III) oxide Cr2O3 5.22 100-120 151.99 2435 200
Zinc oxide ZnO 5.61 20-60 81.41 1975 140
Nickel(II) oxide NiO 6.67 50-100 74.69 1955 160
The physical properties such as density, specific surface area, molar mass, melting point
and cost of procured Nanoparticles are shown in table 3. The mass of Nanopowder required
for TIG welding of HSLA steel is calculated and mentioned in table 4. The calculation of
mass is based on the density of Nanopowder and volume. The length of the coating is 10cm,
and width of the brush is 1cm. The thickness of the flux coating is approximately 0.015 cm.
The mass calculation is done by multiplying the density of flux powder with volume. GTAW
welding machine utilised in this experiment is completely automated.

Table 4 Mass of nano-powders used for experiment

Length
Thickness Mass of
of the Width Density ρ
Flux IUPAC name of flux of coating powder
strip (cm) (gm/cm3)
(cm) (gm)
(cm)
TiO2 Titanium (IV) oxide 10 1 0.015 4.23 0.63
SiO2 Silicon dioxide 10 1 0.015 2.65 0.39
Cr2O3 Chromium(III) oxide 10 1 0.015 5.22 0.78
ZnO Zinc oxide 10 1 0.015 5.61 0.84
NiO Nickel(II) oxide 10 1 0.015 6.67 1.01

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 A Study of Pftig and Fbtig Welding Process on Bead Morphology Using Nanoparticles on
15cdv6 Steel

In Flux bounded TIG (FBTIG) welding a narrow gap called flux gap was managed in the
centre of the plate, and TiO2 Nano flux was pasted on both sides of the flux gap. Experiments
were conducted using flux gap of 3, 4, 5 and 6mm. The photograph of PFTIG welded bead on
the plate using TiO2 nanoparticles and FBTIG weld trial using 3mm flux gap is represented in
figure 1. The bead on plate weldments was pierced transversely followed by polishing and
etching and the specimens were subjected to the optical macrographic test. The etchant used
in this study was a mixture of 10 ml glycerol, 10 ml HNO3 and 20 ml of HCL known as
glycergia. The image J software is utilised to measure the bead morphology variables such as
DOP, BW and HAZ width. The arc voltage is measured from the display of the automated
GTAW welding equipment. The image of the arc profile is captured with the help of a device
that is a charge coupled or CCD detector.

Figure 1 shows the photograph of (a) PFTIG and (b) FBTIG welded bead on plate trials using TiO2
Nano powder.

3. RESULTS AND DISCUSSIONS

3.1. Effect of nano fluxes on bead geometry
The macrograph of weld-bead profiles using conventional GTA welding and Nano powdered
particles are illustrated in figure 2. The shallower penetration is obtained while using Cr203
flux and autogenous TIG welding i.e., 3.247 mm and 4.387 mm, but a deeper penetration of
4.771 and 4.978 mm is generated using ZnO and NiO nano fluxes. The TiO2 and SiO2
nanopowder exhibited much-rooted penetration i.e., 5.936 and 5.475 mm and slender bead
width while correlating with conventional GTA welding and other Nanopowders. The output
variables generated from the bead morphology, i.e., DOP (depth of penetration), BW (bead
width), HAZ (heat affected zone) width and DWR is shown in table 5.

Figure 2 Macrograph of conventional TIG and Nano powdered welds (a) Conventional TIG welding,
(b) TiO2 flux, (c) SiO2 flux, (d) Cr2O3 flux, (e) ZnO flux and (f) NiO flux

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 Skariya P D, Satheesh M, Edwin Raja Dhas and Suneesh E

The PFTIG welds show higher penetration capability while comparing with conventional
TIG weld trials and Cr203 flux. The escalated DOP and slender BW can be attributed to the
phenomenon of reversal of Marangoni convection [16] According to Marangoni convection;
the surface tension gradient decreases with a rise in temperature. During PFTIG welding, the
Nanopowders decompose due to the high intensity of arc temperature and surface active
components such as oxygen, sulphur etc release from the flux [17]. These elements induce a
higher surface tension in the molten pool and fluid flows from low temperature to high-
temperature areas. This phenomenon is termed as a reversal of Marangoni flow, and hence
deeper penetration and slender bead width were obtained.

Table 5 Bead geometry from macrostructure of normal TIG and nano-oxide fluxes

Depth of Bead HAZ Depth to

Nano flux penetration width width width ratio
(mm) (mm) (mm) (DWR)
Normal TIG/No flux 4.387 9.399 2.624 0.467
TiO2 5.936 7.118 2.469 0.834
SiO2 5.475 7.394 2.754 0.740
Cr203 3.247 8.733 2.749 0.372
ZnO 4.771 7.963 2.636 0.599
NiO 4.978 7.728 2.589 0.644
The dimensions of bead morphology variables obtained from the macrograph is shown in
figure 3. The aspect ratio or depth to width ratio is a division of DOP by BW. The optimum
weld bead indicates a higher aspect ratio [18]. The conventional TIG and Cr203 flux show a
lower aspect ratio because of its shallower penetration, whereas larger aspect ratio was
obtained for TiO2 and SiO2 Nano fluxes due to its deeper penetration and slender bead width.
The aspect ratio of conventional TIG welds and Nanoparticles is shown in figure 4.

Figure 3 Dimensions of bead geometry variables using Normal TIG and Nano fluxes

Figure 4 Aspect ratio produced with Normal TIG and Nanoparticles

3.2. Effect of nano fluxes on arc voltage and arc divergence angles
The arc voltage was found to be lower while using Cr203 flux and normal TIG welding,
whereas ZnO and NiO fluxes show a marginal increase in voltage. The voltage of arc was
found to be higher with the use of TiO2 and SiO2 Nano fluxes, and arc voltage difference of

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 A Study of Pftig and Fbtig Welding Process on Bead Morphology Using Nanoparticles on
15cdv6 Steel

2V observed in these cases while comparing with conventional TIG and other Nanopowders.
The decomposition of TiO2 and SiO2 Nano fluxes liberates more positive ions, and attracts
electrons and found that arc is constricted. The arc constriction observed with the use of TiO2
and SiO2 fluxes were attributed to its arc voltage values while PFTIG welding. The
phenomenon of arc constriction is also an important factor for the deep penetration obtained
while using these fluxes [19]. The arc voltage values obtained in normal TIG and Nano
powdered welds are shown in figure 5.

Figure 5 Arc voltages obtained with Normal TIG and Nano flux welds
The arc divergent angles were found to be lower while using TiO2 and SiO2 nano fluxes.
The normal TIG and other Nano powdered welds show a higher arc divergent angles. This
was strongly supported by the matter that arc constriction does not occur in these cases. The
arc voltage values were observed to be higher while using TiO2 and SiO2 nano fluxes and lead
to the arc constriction and hence the divergent angles are lowered. The deeper penetration
obtained while using these fluxes can be attributed to the values of arc voltages and arc
divergent angles. The arc divergent angle in degrees for normal TIG and nano powdered
welds is shown in figure 6.

Figure 6 Arc divergent angles with Normal TIG and Nano flux welds

3.3. Effect of flux gap on bead morphology

The bead morphology dimensions with various flux gaps is shown in table 6 and compared
with the conventional TIG weld and PFTIG weld using TiO2 flux. The dimensions of bead
geometry obtained in PFTIG welding indicate that maximum penetration was procured for
TiO2 Nano flux. The Flux bounded TIG (FBTIG) welding bead on plate trials were conducted
using this flux. The flux gap has a remarkable effect on penetration and aspect ratio. The
complete penetration of 6.384mm and a higher aspect ratio of 0.914 were obtained while
using 3mm flux gap and full penetration was not secured using other gaps. This was due to
the insulation effect which was the significant phenomenon behind FBTIG welding [20]. The
activating flux acts as an insulating lay, r and it resists the flow of electrons to the plate
through the flux. The flux gap provides a channel for the free flow of electro, s and the
generated heat travels through the thickness of the plate and leads to a deeper penetrated weld
bead. When the flux gap is more, the conduction area is also found to be wi, e and some

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 Skariya P D, Satheesh M, Edwin Raja Dhas and Suneesh E

electrons flow along the surface of the plate. The experimental results indicate that the
penetration and aspect ratio found to be lower with an increase in flux gaps. This was
attributed to the insulation effect of activating fluxes.

Table 6 Bead geometry obtained from Normal TIG, PFTIG and various flux gaps
Aspect
Depth of Bead
ratio
Flux gap (mm) penetration width
(DWR
(mm) (mm)
ratio)
Normal TIG/No
4.387 9.399 0.467
Flux
PFTIG (TiO2 Flux) 5.936 7.118 0.834
3 6.384 6.986 0.914
4 5.978 7.559 0.791
5 5.573 7.967 0.700
6 4.738 8.761 0.541
The FBTIG weld bead on plate trial with 3mm flux gap is shown in figure 7. The
penetration of 8.761 mm and aspect ratio of 0.541 was found to be lower in 6mm flux gap,
and the matter supported that the conduction area is more in this gap and the flow of electrons
occurs through both the thickness and the surface of the plate. The decomposition of the flux
powder is also found to be lower with a higher flux gap because heat cannot decompose the
flux when the coating is far away from the weld line. The lower dissociation results in the
absence of surface active elements in the molten pool and leads to lower penetration and
aspect ratio as found similar to normal TIG welding.

Figure 7 Macrograph of FBTIG weld bead on plate trial with 3 mm flux gap

4. CONCLUSION
The welding of 15CDV6 HSLA Steel using PFTIG and FBTIG process with the help of
nanopowders completed successfully and remarkable outcomes from this research are given
below:
• The TiO2 flux provides the maximum penetration in 6.2 mm 15CDV6 steel bead
on plate weld. The single pass autogenous TIG welding with DCEN source was
utilised to weld HSLA steel plate.
• The conventional TIG welding has no remarkable effect on DOP and DWR. The
PFTIG welding with Nano fluxes indicates that Cr203 flux secures less penetration
than normal TIG welding.
• The arc constriction phenomenon was found while using TiO2 and SiO2 nano
fluxes and is evident from the values of arc voltages and arc divergent angles.
• The full penetration is achieved in FBTIG welding process with the assistance of
TiO2 Nano flux. The complete penetration and maximum aspect ratio were found
with the use of 3 mm flux gap.

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 A Study of Pftig and Fbtig Welding Process on Bead Morphology Using Nanoparticles on
15cdv6 Steel

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