2005 During manufacture of agglomerated weld fluxes the raw materials are very finely ground, Figure 3.7. After weighing and with the aid of a suitable binding agent (water- glass) a pre-stage granulate is produced in the mixer. Manufacture of the granulate is finished on a rotary dish granulator where the individual grains are rolled up to their desired size and consolidate. Water evaporation in the drying oven hardens the grains. In the annealing fur- nace the remaining water is subsequently re- moved at temperatures of between 500C and 900C, depending on the type of flux.
The fused welding fluxes are characterised by high homogeneity, low sensitivity to moisture, good storing properties and high abrasion re- sistance. An important advantage of the agglomerated fluxes is the relatively low manufactur- ing temperature, Figure 3.8. The technological properties of the welded joint can be improved by the addition of temperature-sensitive deoxidation and alloying constituents to the flux. Ag- glomerated fluxes have, in general, a lower bulk weight (lower consumption) which allows the use of compo- nents which are reacting among themselves during the melting process. How- ever, the higher susceptibil- ity to moisture during stor- age andprocessing has to be taken intoconsideration. Different Welding Flux Types According to DIN EN 760 br-er3-09e.cdr MS CS ZS RS AR AB AS AF FB Z MnO + SiO CaO 2 min. 50% max. 15% manganese-silicate CaO + MgO + SiO CaO + MgO 2 min. 55% min.15% calcium-silicate ZrO + SiO + MnO ZrO 2 2 2 min. 45% min. 15% zirconium-silicate TiO + SiO TiO 2 2 2 min. 50% min. 20% rutile-silicate Al O + TiO 2 3 2 min. 40% aluminate-rutilel Al O + CaO + MgO Al O CaF 2 3 2 3 2 Al O + SiO + ZrO CaF + MgO ZrO 2 3 2 2 2 2 Al O + CaF 2 3 2 CaO + MgO + CaF + Mo SiO CaF 2 2 2 min. 40% min. 20% max. 22% aluminate-basic min. 40% min. 30% min. 5% aluminate-silicate min. 70% aluminate-fluoride-basic min. 50% max. 20% min. 15% fluoride-basic other compositions Figure 3.9 ISF 2002 Properties of Fused and Agglomerated Welding Fluxes br-er3-08e.cdr Properties uniformity of grain size distribution grain strength homogeneity susceptibility to moisture storing properties resistance to dirt current carrying capacity slag removability high-speed welding properties multiple-wire weldability flux consumption 1) assessment : -- bad, - moderate, + good, ++ very good 2) core agglomerated flux Fused fluxes 1) Agglomerated fluxes 1) +/++ +/++ +/++ +/++ +/++ +/++ -/++ -/+ -/++ -/++ -/++ -- /++ 2) +/++ +/++ +/++ +/++ +/++ --/+ -/+ -/+ -/++ +/++ Figure 3.8