Improving the Accuracy of Silicon Transfer Prediction in Submerged Arc Welding: A Multi-Reaction-Zone Analysis

This study aims to predict and evaluate the transfer behavior of silicon employing SiO2-bearing fluxes during submerged arc welding. Unlike previous studies that only focused on chemical reactions in the weld pool zone, this research investigates the elemental behavior of silicon subjected to essential reaction zones in a submerged arc welding process. The proposed method is compared with the traditional thermodynamic equilibrium models, enhancing the understanding of silicon transfer behavior in the submerged arc welding process. It is demonstrated that relying solely on thermodynamics within the weld pool zone is inadequate for accurately predicting the extent of silicon transfer level since the loss of silicon during the droplet zone and the improvement in oxygen content in the molten droplet are not considered, resulting in an overestimation of the & UDelta;Si level. Finally, the limitations of the traditional elemental transfer quantification method and corresponding corrective suggestions are proposed.