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Um método para estabelecimento do processo de dissociação térmica dos óxidos na zona de reação durante soldagem e deposição por
arco submerso é apresentado. Foram desenvolvidas equações não lineares combinadas para definição da composição da mistura gás-
vapor. Estas descrevem a dissociação dos óxidos do tipo MeO, MeO2 e Me2O3. Cálculos dos processos de dissociação dos óxidos foram
feitos para óxidos que são comumente incluídos em fluxos de soldagem. Os resultados e análises são apresentados. O método proposto
parece ser adequado e aplicável para análises de processos durante operações a arco submerso as quais acontecem com fases gasosas.
Palavras-chave: soldagem por arco submerso, fase gasosa, dissociação térmica dos óxidos gasosos, cálculos termodinâmicos,
mecanismos de dissociação
Abstract: A method of settlement of the process of thermal dissociation of oxides in reaction zone during the submerged arc welding and
welding deposition is presented. Combined non-linear equations for definition of gas-vapour mixture composition were developed. They
describe the dissociation of MeO, MeO2 and Me2O3 types of oxides. Calculations of the processes of oxide dissociation were performed
for the oxides that are commonly included into welding fluxes. Their results and analysis are presented. The method proposed appeared
to be adequate and applicable for analysis of processes during submerged arc operation that run in the gas phase.
Key-words: submerged arc welding, gas phase, thermal dissociation of gaseous oxides, thermodynamic calculations, mechanism of
dissociation
1. Introduction processes in the reaction zone and the final chemical content
of the weld metal [2, 4-6]. The fact that these reactions are
The metallurgical processes run during the submerged arc not taken into account in the results, a very low correlation is
welding (SAW) still remain unstudied from the point of view of achieved between experimental data and calculation performed
physical and chemical interaction in the reaction zone. This is basing of the flux content and welding parameters. The reason is
due to formal approach to the analysis of metallurgical reactions, these calculations were limited by the slag-metal boundary zone.
which is performed for the slag-metal boundary zone only. In the calculations the theories of molecular and ion structure
As a result the classification of fluxes based on their basicity were applied to the slag which allowed to predict non-metal
is commonly used in present time. This makes it impossible to inclusions in the weld metal. A range of models is currently used
calculate the oxygen content in the weld metal as well as that for calculations. They include models which connect chemical
of alloying elements, silicon and manganese in the first place. composition of the weld metal and composition of the slag by
Development of new fluxes is often based on empiric methods means of empiric equations [7-9] and multilevel regression
as a result of total ignorance of gas phase and reactions run on combined polynomic equations [10].
its boundaries. At present time there are no methods of calculation of gas phase
During the submerged arc welding process, the reaction zone composition known. On the other hand, there is no doubt that
consists of three phases: metal; slag; and gas [1-4]. The gas oxides contained in the flux are intensively vaporized and often
phase is highly heated and experimental methods can be hardly sublimate under the welding arc heat. As a result, the gas phase
applied for its analysis [2-4]. However, many researchers composition differs from the original one due to oxide content,
consider the gas phase to intensively influence the metallurgical the oxides are transferred to the gas phase directly. This fact
makes it possible not to take into account the liquid phase. For
the further calculation of their thermal dissociation principles
of equilibrium thermodynamics of gaseous compounds are
Recebido em 19/04/2013, texto final em 12/07/2013. used. Thermal dissociation of gaseous oxides under the arc
temperature in the front section of the welding pool is run in
314 Soldag. Insp. São Paulo, Vol. 18, Nº. 04, p.314-321, Out/Dez 2013
Peculiarities of Thermal Dissociation of Oxides during Submerged Arc Welding
Figure 1. Patrtial pressure values of reaction products in thermal dissociation of SiO2; Al2O3; CaO; MgO; TiO2; MnO oxides
(according to data presented in [15])
Figure 2. Patrtial pressure values of atomic and molecular oxygen in thermal dissociation of SiO2; Al2O3; CaO; MgO; TiO2; MnO
oxides (according to data presented in [15])
Soldag. Insp. São Paulo, Vol. 18, Nº. 04, p.314-321, Out/Dez 2013 315
Leonid Zhdanov, Vladyslav Kovalenko, Nataliya Strelenko, Yevgenia Chvertko
theory of metallurgical processes [11-15]. These processes are the overheated gas-vapor mixture starts to cool down. The
analysed one-sidedly: it is considered that as a result of thermal chemical processes which can be considered to be recombination
dissociation of lower oxides the reaction products contain the (reverse to dissociation) ones are run. If the reactions run in the
element itself (in the original state) and molecules of oxygen arc plasma are not taken into account [2, 4, 9, 16] and the zone
(rarely – oxygen in atomic state). When the oxide appears to be to be analyzed is limited by the overheated gas-vapor mixture
a result of reaction between solid or molten metal and oxygen behind the arc, then all the reactions to be described will be
the equilibrium constant includes only one parameter – oxygen those of formation of various gaseous compounds from gaseous
partial pressure which is considered to be the oxide dissociation components. As a result estimated values of partial pressure of
pressure (dissociation tension). More reasonable approach is gaseous components will be defined.
presented in [14], where the oxide dissociation into metal and The main task on the first stage of gas phase analysis is
gas is analysed taking into account equilibrium between molten development of the method of calculation of thermal dissociation
metal and gas. of oxides in gaseous state.
The method developed by I. Kulikov allows to predict if
a new condensed phase is formed as a result of thermal 4. The method of settlement of dissociation of gaseous
dissociation of chemical compound. The method resulted in oxides of MeO, MeO2, Me2O3 types
calculation of partial pressure of components of the condensed
oxide – system of gaseous components that includes oxygen, To define the gaseous mixture composition the models
intermediate oxides and metals. In this method the reactions are made describing the processes run under heating. The
of dissociation are considered to run in parallel. The analysis combined reactions are chosen on basis of data about qualitative
of results of calculations according to method [15] has shown composition of the mixture to be analyzed. The temperature
that in dissociation every oxide provides its own composition of rise leads to increase of the number of reactions in the gaseous
gaseous phase (see Fig. 1, 2). These results qualitatively respond state. These data can be obtained as a result of thermo dynamical
the real state in the range of temperature under study. analysis of all possible reaction of thermal dissociation of oxides
The principle of reactions being parallel, on which this calculation in the gaseous state. It is reasonable to perform such analysis by
method is based, makes it impossible to take into account the the values of Gibbs energy taking into account the stoichiometric
further dissociation of gaseous oxides being products of the first coefficients of reactions’ components. Next the main reactions
reaction under temperature rise. As a result the partial pressure can be chosen on the priority basis, those describing the gaseous
of metals, gaseous oxides, molecular and atomic oxygen oxide dissociation. Every combined reaction can be operated as
gradually increases as the temperature rises. Still it is obvious an independent thermo dynamical system with its own working
that the temperature rise should result in their following partial formulas for estimation of roots of non-linear equations.
dissociation, but this process isn’t included into the I. Kulikov’s Equilibrium of the reactions in such system is characterized by
method. If the temperature value is higher then 3250 – 3500 the equilibrium constant. The definition of gas phase composition
K, the partial pressure of gaseous oxides exceeds its highest requires a solution of non-linear combined equations and is
possible value and the method becomes inadequate. The same usually made on PC. The most important and critical step of the
situation refers the molecular oxygen, for which reaction of its gas phase composition estimation is the choice of the reactions.
generation should be analysed in parallel with its dissociation. The limit temperature values for analysis were chosen equal to
the gas phase gradient, which is limited by the temperature of
3. Peculiarities of thermal dissociation of oxides during boundaries of the arc (approximately 6000 K) and molten slag
SAW process (1400 K).
The process of thermal dissociation of gaseous compounds is
In SAW partial pressure of oxygen in the oxide-metal-oxygen characterized by the degree of dissociation x and equilibrium
system is defined with the assumption that both oxide and metal constant of the reaction. The last can be calculated on the basis
are in condensed state and the other components are formed of the Van’t Hoff equation and figured through the partial
as a result of vaporization processes. In this case none of the pressure values of reaction components. These values depend
methods mentioned above is applicable due to the fact that in arc on the degree of thermal dissociation and the mole concentration
welding the processes of direct vaporization substantially define of the components.
the quantitative composition of the gas phase components. The The method of settlement of thermal dissociation of gaseous
oxides contained in the flux sublimate under the arc energy, turn oxides of MeO, MeO2, Me2O3 types was developed taking into
into gaseous state with further thermal dissociation in this state. account reactions which are run simultaneously in parallel and
The dissociation process turns into recombination when the in series. This method assumes formation of new (intermediate)
temperature decreases. gaseous compounds. The thermal dissociation is considered
The effect of arc on the metal in SAW process isn’t uniform. to take place in a homogeneous system. The decreasing of
Greater part of the arc energy is applied to the front of the the temperature is assumed to cause reverse processes of
reaction zone where it is absorbed by materials melting and recombination.
vaporizing. They traverse the arc plasma and its border zones The final product of the method is a combined equation
and as a result the gas phase is formed with the arc in its front which describes relationship between equilibrium constant
section. Behind the arc, in the ‘tail’ section of the reaction zone of the reaction and the degree of dissociation of the reaction
316 Soldag. Insp. São Paulo, Vol. 18, Nº. 04, p.314-321, Out/Dez 2013
Peculiarities of Thermal Dissociation of Oxides during Submerged Arc Welding
64 x15 ⋅ (1 − x3 ) (1 − x2 )
4
2(x1 − x1 x3 ) K ′p =
N MeO =
∑n
(6)
(1 − x1 )2 (2 + 3x1 + x1 x2 + 2 x1 x3 ) ; (19)
- reaction 17:
2(x1 − x1 x2 )
N O2 = 64 x14 x34 ⋅ ( x2 + x3 )
4
∑n (7)
K ′p′ =
(1 − x3 )4 (2 + 3x1 + x1 x2 + 2 x1 x3 )4 ; (20)
2(x1 x2 + x1 x3 )
NO = (8) - reaction 18:
∑n 4 x1 ⋅ (x2 + x3 )
2
K ′p′′ = (21)
N Me
2x x
= 1 3
(9)
(1 − x2 )(2 + 3x1 + x1 x2 + 2 x1 x3 )
∑n The general equations obtained describe the process of parallel
and series dissociation of molecules of MeO (14-15), MeO2 (10-
The equilibrium constants of the reaction of parallel three-
12) and Me2O3 (19-21) types taking into account temperature and
stage dissociation will be described by the following analytical
individual values of thermo dynamical characteristic functions
equations:
Soldag. Insp. São Paulo, Vol. 18, Nº. 04, p.314-321, Out/Dez 2013 317
Leonid Zhdanov, Vladyslav Kovalenko, Nataliya Strelenko, Yevgenia Chvertko
318 Soldag. Insp. São Paulo, Vol. 18, Nº. 04, p.314-321, Out/Dez 2013
Peculiarities of Thermal Dissociation of Oxides during Submerged Arc Welding
Soldag. Insp. São Paulo, Vol. 18, Nº. 04, p.314-321, Out/Dez 2013 319
Leonid Zhdanov, Vladyslav Kovalenko, Nataliya Strelenko, Yevgenia Chvertko
Aluminum oxide Al2O3 reactions taking into account the fact they run in parallel. These
Significant changes of the gas phase during the Al2O3 dissociation equations make it possible to perform calculations for all the
start from the temperature 4500 K. The mole fraction of the oxides contained in the welding fluxes.
atomic oxygen and gaseous aluminum decrease and those of the 3. It was determined that every oxide has its own scheme
aluminum monoxide and molecular oxygen increase. They reach of thermal dissociation which is determined by the thermo
their maximums of 61 % and 12.5 % correspondingly at 3250 K. dynamical characteristic functions of the reaction components
When the temperature is lower then 3400 K the gaseous phase and by the combined equation which relate the degree of
contains Al2O3. The atomic oxygen and aluminum disappear dissociation and the equilibrium constant.
from the mixture after 2800 K (see Fig. 9). At this temperature 4. All the oxides, even those of the same type, during their
the Al2O3 oxide starts to condensate. dissociation evolve the molecular and atomic oxygen to the
gaseous mixture. The mole fraction values of the molecular and
atomic oxygen depend on the temperature.
5. The data obtained for dissociation of gaseous oxides allow to
perform numerical and qualitative analysis of the gaseous phase
during the SAW process.
7 References
320 Soldag. Insp. São Paulo, Vol. 18, Nº. 04, p.314-321, Out/Dez 2013
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