Influence of Saw Fluxes on

Low-Carbon Steel Weld Microstructure

J.-W. JANG, S. S H A H , and J. E. I N D A C O C H E A

The influence of submerged-arc flux composition on the inclusion morphology and weld
metal microstructures of low carbon steels is investigated. Systematic weld oxygen varia-
tions and changes in inclusion shape and size are obtained by changing the welding flux
composition. The influence of inclusion content, morphology, and distribution on achiev-
ing specific types of weld metal ferrite is described.

INTRODUCTION basic counterparts. Formations of bainitic microstructures

The submerged-arc welding process was developed in
response to demands for a welding procedure with high
deposition rates. Its applicability, however, was initially
confined to cases where the mechanical property require-
ments were limited. Attempts were made to produce
submerged arc welds with properties comparable with those
of low hydrogen manual metal arc welds. ~,2 But such welds
were found to contain more inclusions, oxygen, and silicon
than gas metal arc welds produced with the same filler rod
and base material. 3
The deleterious effect of high oxygen on the impact prop-
erties of submerged-arc weld deposits is well documen-
ted. 2'4-s Conventional submerged-arc welding of steels
employs oxide-bearing fluxes and oxygen-bearing electrode
wires. Thus, fluxes containing large amounts of relatively
easily reduced oxides, such as FeO and SiO2, will produce
welds containing large amounts of oxygen. 9`~~ Replace-
ment of such constituents with more stable oxides or non-
oxygen bearing components will result in welds containing
low oxygen.
The general observation that microstructure depends criti-
cally on flux formulation for a given weld parameter is made
by several investigators. 8'~2-~8It is observed that acidic-flux
weld deposits contain higher levels of oxygen than their
J. -W. JANG, S. SHAH, AND J. E. INDACOCHEA are with
the Department of Civil Engineering, Mechanics and Metallurgy,
University of Illinois at Chicago, P.O. Box 4348, Chicago, IL
60680.
J. MATERIALSFOR ENERGYSYSTEMS 9 1987 ASM INTERNATIONAL
are observed in welds processed with acidic submerged-arc
welding fluxes. Using basic fluxes, the welds contained low
oxygen and a highly acicular ferrite microstructure.
A general agreement appears to exist that a weld micro-
structure containing primarily acicular ferrite will show
great strength and excellent toughness due to its small
grain size, high dislocation density, and high angle grain
boundaries.~9 However, the presence of proeutectoid grain
boundary ferrite, ferrite plates with aligned M-A-C
(martensite-austenite-carbide), or bainite is considered
deterimental to the toughness of the weld, due to the fact
that these constituents provide paths for easy crack propa-
gation. Therefore attempts have been made to determine
ways of controlling the acicular ferrite content of the
weld metal. 2~
The primary objective of this work was to establish a
correlation between the ferrite morphologies and the inclu-
sion characteristics (i.e., volume fraction, composition, and
shape) of steel welds, since it is known that oxygen influ-
ences the austenite to ferrite transformation through the
presence of inclusions. Welds were made using three differ-
ent flux systems (SiO2-MnO-FeO, SiO2-MnO-CaF2, and
SiO2-CaO-CaF2) that are known to produce welds with very
high and very low oxygen levels, in order to monitor the
effect of flux composition on the inclusion characteristics.
The same filler wire electrode and base plate were used
for all welds (Table I), while the welding parameters were
adjusted to produce three heat inputs (Table II). Qualita-
tive and quantitative metallography was performed on all
the welds.
VOL. 8, NO. 4, MARCH 1987 391
 Table I. Base Metal and Filler Metal Compositions

Composition (Wt Pct)

Material C Mn P S Si Ti AI
Base metal 0.04 0.37 0.012 0.022 0.03 0.003 0.001
Filler metal 0.09 1.18 0.007 0.013 0.58 0.002 <0.008

with the inclusion volume fraction for all the flux systems
Table II. Welding Process Parameters studied in this investigation. Since the oxygen in the weld
metal is dependent on the quantity and stability of the
Voltage 33 volts 31 volts 28 volts oxide constituents of the flux, the welds made with the
Current 600 amps 330 amps 550 amps SiO2-MnO-FeO fluxes showed larger quantities of oxygen
Travel speed 12.2 in/min 12.2 in/min 11.88 in/min
Wire speed 75 in/rain 40 in/min 70.0 in/rain with larger additions of FeO because iron oxide is more
Heat input 97.4 kJ/in 50.3 kJ/in 77.8 kJ/in unstable than manganese oxide. In the case of the
3.83 kJ/mm 1.98 kJ/mm 3.0 kJ/in SiO2-MnO-CaF2 system, the behavior is reversed due to
the fact that manganese oxide is being replaced by a non-
oxygen bearing component, calcium fluoride. Figure 5
INCLUSION CHARACTERIZATION shows the variation of oxygen in the weld metal in terms of
flux composition.
As-polished weld samples were examined for inclusion Along with changes in the morphology and the volume
shape, size distribution, and volume fraction. It is observed fraction of the inclusions, a refinement is observed as the
that the composition of the flux affects the shape and the size weld metal oxygen content decreases. Figure 6 is a plot of
of the inclusions. Welds produced with the 40 wt pct inclusion size as a function of flux composition for two of
SIO2-60 wt pct MnO flux have predominantly spherical in- the flux systems examined.
clusions that become primarily irregular and complex in
shape as systematic additions of FeO were made at the
expense of MnO, with the silica held constant. On the other FLUX BASICITY
hand, the weld inclusions remained fairly spherical, with Tuliani et al. 22 proposed a basicity index, BI, formula which
just a decrease in size, when CaF2 additions were made to is the most popular:

CaO + CaF2 + MgO + K2O + Na20 + Li20 + 1/2(MnO + FeO)

BI=
SiO2 + 1/2(A203 + TiO2 + ZrO2)

the SiO2-MnO flux. Figure 1 denotes the changes observed
in the inclusion morphology for these two flux systems. The
inclusions in the welds processed with the SiOz-CaO-CaF2
flux systems vary in shape from spherical to irregular and
other geometric forms such as triangular and square, as
shown in Figure 2.
Inclusion volume fraction and size measurements were
performed according to ASTM Standard E45 with readings
taken at six locations using a magnification of 1600x.
Welds from the SiO2-MnO-FeO flux system had the highest
inclusion levels which increased with larger additions of
FeO to the flux as seen in Figure 3. The welds processed
with SiO2-MnO-CaF2 fluxes showed a decrease in the inclu-
sion level with greater substitutions of CaF2 for MnO, as
observed in Figure 3. This behavior is expected, since
oxygen is present in welds primarily in combined form as
non-metallic oxide inclusions due to the low solubility of
oxygen in iron. Figure 4 correlates the weld oxygen content
It was found that, in general, the higher the basicity the
cleaner the weld in regard to nonmetallic inclusions. It has
been reported ~2'16that high-flux basicity reduces weld metal
oxygen levels and improves toughness. This correlation be-
tween flux basicity and weld oxygen content for the welds
produced in this investigation is shown in Figure 7. In the
case of SiO2-CaO-CaF2 flux system, the weld metal oxy-
gen content is reduced as the SiO2 level of the flux is de-
creased from 40 wt pct to 20 wt pct which corresponds to
increases in the basicity index from 1.6 to 4.0. For each
SiO2-CaO-CaF2 flux system, at a fixed silica level, no
changes in the basicity index are possible since CaO and
CaF2 have the same coefficient. This would imply a constant
weld oxygen level for each of the fluxes of the same silica
level. Figures 8 and 9 show weld oxygen contents and inclu-
sion volume fractions which remain fairly constant. Further,
the inclusion size remains uniform in each SiO2-CaO-CaFz
flux system as the CaO and CaF2 amounts are varied. Size

392 VOL.8, NO. 4, MARCH 1987 J. MATERIALSFOR ENERGY SYSTEMS

Fig. 1--Inclusion morphologies in welds produced with SiO2-MnO-FeO fluxes, (a) and (b), and SiO2-MnO-CaF2 fluxes, (c) and (d).
changes occur only when the silica level is altered, as shown
in Figure 10.
WELD METAL MICROSTRUCTURE
Changes in the weld metal microstructure, particularly in the
ferrite morphology, were found to be very apparent with
variations in flux composition. The primary constituents
identified in the as-deposited weld microstructure of this
investigation are proeutectoid grain boundary ferrite which
may be allotriomorphic or blocky in appearance, primary or
secondary side plate ferrite, intragranular plate-like ferrite
(aligned M-A-C, martensite-austenite-carbide), acicular fer-
rite and bainite. These microconstitutents are presented in
Figure 11. The changes in the microstructure of the weld
metal were primarily correlated with the weld metal oxygen
content. The manganese level was also found to affect the
microstructure indirectly through hardenability.
The weld samples produced with the SiO2-MnO-FeO flux
system had the highest oxygen contents, between 1200 and
1400 ppm, as seen in Figure 5. At these levels of oxygen,
however, variations of about 200 ppm did not appear to alter
J. MATERIALS FOR ENERGY SYSTEMS
the weld microstructure in terms of the acicular ferrite. The
acicular ferrite volume fraction remained constant at 30 pct
with greater additions of FeO replacing MnO in the
SiO2-MnO-FeO flux system, as seen in Figure 12. An in-
crease of proeutectoid grain boundary and polygonal ferrites
was also noticed. Such changes in ferrite morphologies,
coupled with the increase in inclusion density and size,
imply that ferrite nucleates at these inclusions in addition to
the grain boundaries.
Quantitative metallography was performed on weld sam-
ples of intermediate to high oxygen levels (400 ppm to
1400 ppm) produced with the SiO2-MnO-CaF2 flux system.
It was observed that as the amount of oxygen in the welds
decreased, the volume fraction of acicular ferrite increased,
as shown in Figure 13. This suggests that since the inclu-
sions decrease in size, as a result of the lower contents of
oxygen in the welds, these will become activated at very
large undercoolings. With such large undercoolings, the
austenite will transform to ferrite at the low temperatures of
the acicular ferrite range. There are two data points (welds
containing 490 and 1440 ppm of oxygen) in Figure 13, how-
ever, that seem to contradict this observation, but the man-
VOL. 8, NO. 4, MARCH 1987 393
Fig. 2--Inclusion morphologies in welds produced with 40 wt pct SiO2-CaO-CaF2 fluxes, (a) and (b), and 20 wt pct SiO2-CaO-CaF2 fluxes, (c) and (d).

I.I
SlO ! 9 4 0 % (r 9
1.0

_~o.9
a-
0 9
0.8

0
0.7
o

~0.6

_1
0.5 FIO or CoF 2 IN THE FLUX (wt %)

I l I I
0.4 60 55 50 4,5 4O

MnO IN THE FLUX ( w t %]

0.3 I ,,I I I I
0 5 I0 15 20 9 s;o~; - , , o - F.o, 0 SlO z- , , . o - r z

Fig. 3--Inclusion proportion in welds as function of FeO and CaF2 for SiO2-MnO based fluxes.

394 VOL. 8, NO. 4, MARCH 1987 J. MATERIALS FOR ENERGY SYSTEMS

 )0
1.0
SIO= 9 40 % (constant)
)0

0.9
9 9 I0

0.8
/ / TO 0 . 6 IJm

Z
9 07
I.-
0
<
/../ 6(1

E
w
0.6 / / 5C

J
0 4(1
> 0.~
/

//.7
Z
0
3C p ~ , /t,,- J
.J
0
Z
0.4
~ 9 4 0 % SiO2 - MnO - FeO
2r
//~/~A/
- \
I. 3 IJm

/7
9 40 % SiO2" M n O - C o F 2
02 9 4 0 % SiO2 CoO CoFz
t~ 3 0 % S i O z C o O CoF2 IC

0.2 /oo/ 0 20 % SiOz CoO CaF2

Oi
i ~--

0
|
--4
I
5
9
q
I0
I
q
15
9
I~I
20 25
I.g
l
lJm

FsO or CaF z IN THE FLUX (wt %)

0.1 I I I 1 I I
200 400 60O 800 I000 1200 I I I I I I
60 55 50 45 40 35
WELD METAL OXYGEN CONTENT ( plan )

Fig. 4 - - I n c l u s i o n volume fraction as function of oxygen in the weld metal MnO IN THE FLUX (it %)
for all the fluxes in this work.
--OAO I|O|-MmO-C=F! ---ill $iO|-illO-FlO

Fig. 6 - - I n c l u s i o n size as function of FeO and CaF2 in SiO2-MnO based

1400
fluxes.

~1300
o
1400 I 0 9 38 % SiO2- MnO - OaF2 FLUX
== oll ~' 9 4 0 % SiOz- CoO- CaF2 FLUX
I- 1200
Z ~t L o 9 30 % S102- Co O- C aFz ' FLUX
W
I-- .= 1200 ~ o 9 20 %StOz-CoO-CoF 2 FLUX
Z t
~ II1~ J.~t .... o &Do LH
~ -- 9 9 9 9 HHI
I000 ql
Z ,.=,
w 0

X o
800 e~~
O

J 900 600 o ~
=E
W

800 t~J
a SlOz 9 40 % (constant) 3
.J "'"D-. Ib
bJ
9 Eutsctlc Flux 200 , /'D-.._~
70C
I 2 3 4
BASICITY INDEX
I I I I I
0 5 I0 15 20 Fig. 7--Correlation between basicity of the experimental fluxes and the
weld os content in this work. LHI and HHI stand for low and high
FoO or CoF l IN THE FLUX (wt %) heat input.
I I I ] 1
60 55 50 45 40
ganese levels of these welds provide a possible explanation.
MnO IN THE FLUX (wt %) The low hardenability of the weld caused by the high oxy-
9 siOz- - , o - yea o mo=- usa - C=F= gen level seems to be more than compensated by the high
Fig. 5 - - O x y g e n in the weld metal as function of FeD and CaF2 in
manganese content. The weld sample containing only
SiO2-MnO based fluxes. 490 ppm of oxygen experiences a reduction of hardenability
J. MATERIALS FOR ENERGY SYSTEMS VOL. 8, NO. 4, MARCH 1987 395
 600 I J)

~50C 0.8
<
i,
0
Z
hi
~-40C 0.~
Z
0
(,.) / A A
/ 0 t,
/ ._.....--
Z
,- 300 0.4
>-
Z
X (2_
0 03
/
2OO 02 o n

tO0 0.( I I I I I I
20 25 30 35 40 45
CoF IN THE FLUX ( wt. % )
I I I I 1 I I I ~ I L I
20 25 3O 35 40 45 40 35 50 25 20 15
CoF t IN THE FLUX ( wt. % ) CoO IN THE FLUX ( wt %), 40 % S;Ot
I I I I l I 1 1 I I I s
40 35 30 25 20 15 50 45 40 55 50 25
CoO IN THE FLUX ( = t . % ), 40 % SI0 t CoO IN THE FLUX" ( wt %), 30 % SiO t
I I I I 1 I I I I I I ,, I
50 45 40 35 :50 25 60 5,5 50 45 40 35
CoO IN THE FLUX ( el. % ), 30 % 5102 CoO IN THE FLUX ( wt. %), 20 % SiOt

I I I I 1 I
60 55 50 45 40 35 0 40 % SiO.
A 30 % $i0~
[3 20 % S=O~
CoO IN THE FLUX ( wt. % ), 20 % SIOt
9 40 % SIO
9 30 % $10'~. Fig. 9 - - Inclusion volume fraction correlated with the CaO and CaF2 in the
9 20 % SiO~ flux SiO2-CaO-CaF~ at three SiO2 levels.
Fig. 8 - - W e l d metal oxygen content for weld specimens produced with
SiO2-CaO-CaF2 fluxes at three SiO2 levels.

I00
+.1 ......... O_. . . . . . . . . L ........ l- ..............
90 9 O O

0 0 Q6 ~m

W t 9 H e --
~ To CoFt IN THE FLUX (wt. % )
W I I I 1 I I
~ so 40 35 5O 25 20 15
0
5O CoO IN THE FLUX ( wt. % ), 40 % SiOt
1 I I 1 I 1
50 45 40 35 30 25
40
),.
CoO IN THE FLUX ( wt+ % ), 30 % SiO•
~ 3o I 1 I I I I
W 9 9 8, 9
60 55 50 45 40 35
~ 2o
F '" ..~._ _ _ 1.3 Mm
CoO IN THE FLUX ( wt % ), 20 % SiOt
I0
.-.~,_--__:__=~___~-._----~=_~~__-~.~ ,~...,. 9 9 9 40 % SlOg
--~ O A O SO % SiO 2
20 25 30 35 40 45 ..... 9 9 gl 20 % $iO 2

Fig. 10--1nclusion size as function of CaF2, CaO and SiO2 levels in the flux.

396 VOL. 8, NO. 4, MARCH 1987 J. MATERIALS FOR ENERGY SYSTEMS

 60
SlO 2 " MnO- CoF2
t?l~
70

60

50
W 9
0 . 8 6 M~
40
bJ
1.46 Mn
tl.

30
.J
U
G
2O

Fig. 11--Typical microconstituentspresent in the weld samples of this I0

investigation:A. bainite;B. secondarygrain boundaryside-plateferrite;C.
intragranular plate-like ferrite with aligned M-A-C (martensite-austenite-
carbide); D. acicular ferrite; E. grain boundary allotriomorphicferrite; I I I I I I I
E blockyferrite. 200 400 600 800 I000 1200 1400 1600

WELD METAL OXYGEN CONTENT (ppm)

Fig. 13--Acicular ferritecontentas functionof oxygenin the weld metal

50 for welds producedwith SiO-MnO-CaF2fluxes.
SiO 2 = 40 %

~e 4 0
I,iJ microconstitutent present, however, was not bainite but
i-'-

I I
primarily proeutectoid grain boundary ferrite. It is apparent
I i
W that the increase in hardenability provided by a reduction in
the oxygen content is diminished by the low manganese
0::
level. Furthermore, the cooling rate may be too slow to
.J
r activate these small inclusions, which are reduced in size as
<[ the oxygen level decreases (see Figure 10). It is possible,
then, that in failing to become ferrite nuclei, these inclusions
i i i
will pin the grain boundaries (Figure 16) causing a refine-
I0 15 20 ment of the prior austenitic grain size. Figure 17 shows
FeO IN THE FLUX ( wt. % ) the micrographs of two weld samples processed with the
I I I I same flux and heat input; however, weld J7Q was quenched
55 50 45 40 after welding. This resulted in a microstructure consisting
MnO IN THE FLUX ( wt. %)
predominantly of acicular ferrite, proeutectoid veining grain
Fig. 12--Acicular ferrite content in welds produced with the SiOT boundary ferrite, and islands of proeutectoid blocky ferrite.
MnO-FeO fluxes.
Sample J7Q also shows a coarser grain size than the micro-
structure of sample J7.
due to the low manganese level. Figure 14 shows the corre- The chemistry of the inclusions in several welds is being
spgnding micrographs of the welds quantitatively examined examined with the X-ray fluorescence unit (EDS) of the
in Figure 13. scanning electron microscope. Inclusions next to regions of
When the oxygen level in the weld metal falls below acicular and proeutectoid grain boundary ferrites were in-
250 ppm, it has been reported that the amount of acicular spected, noting that Mn, Si, A1, and Ti were the primary
ferrite in the weld is reduced and replaced by a low tem- elements present. Preliminary results indicate that these ele-
perature bainite product. 16'23 Quantitative metallography ments are present in greater proportions in those inclusions
was performed on weld samples of the 20 wt pct SiO2- within the acicular ferrite as seen in Figure 18. The com-
CaO-CaF2 flux system which have oxygen levels between positions of the inclusions did not differ from those of adja-
170 ppm and 210 ppm. The results, shown in Figure 15, cent ferrite areas.
denote this decrease in the proportion of acicular ferrite with The topics discussed in this ongoing work are just a few
reduction in the weld metal oxygen content. The other examples of how basic knowledge of the nature of inclu-

J. MATERIALSFOR ENERGYSYSTEMS VOL. 8, NO. 4, MARCH 1987 397

Fig. 14--Photomicrographs of welds produced with 38 wt pct SiO2- MnO-CaF2 fluxes at (a) 62 wt pct MnO, 0 wt pct CaF2; (b) 57 wt pct MnO, 5 wt pct
CaF2; (c) 47 wt pct MnO, 15 wt pct CaF2; (d) 32 wt pct MnO, 30 wt pct CaF2; and (e) 17 wt pct MnO, 45 wt pct CaF2.

398 VOL. 8, NO. 4, MARCH 1987 J. MATERIALS FOR ENERGY SYSTEMS

 20w/o S;Oz - c o O - CoF2

50

w
l-
n.
bJ
b. 40

ix:
<(
.J G64 Mn

30 0.53 Ma

Fig. 16--Scanning electron micrograph showing pinning of the grain

boundary.
I I 1

17'0 180 190 200 210

WELD METAL OXYGEN CONTENT (ppml

Fig. 15--Acicular ferrite content as function of oxygen in the weld metal
for welds produced with 20 wt pet SiO2-CaO-CaF2 fluxes.

Fig. 17--Photomicrographs of welds produced with the same flux, 40 wt pet SIO2-55 wt pet MnO-5 wt pet CaF2. (a) the weld was allowed to cool at room
temperature, sample J7; (b) the weld was quenched in water immediately after welding, sample J7Q.

sions in weld metals can be used. The information provided SUMMARY

here is based on an extensive light microscopy; however,
many questions still remain unanswered because of the lim-
itation of this instrument, but further work will be done at
the submicroscopic level using electron microscopes. It is
clear from the studies carried out to date that more de-
tailed investigations are required before a full understanding
of inclusions, their distributions, and structures can be
obtained.
This microstructural study shows that weld metal oxygen
does have a very significant effect on weld metal phase
transformation characteristics. Particularly, it appears to
have a dramatic effect on the ferrite formation kinetics and
ferrite morphology. The nucleation of polygonal ferrite and
other high temperature ferrites was found to occur more
readily in high oxygen deposits, and this was a direct result

J. MATERIALS FOR ENERGY SYSTEMS VOL. 8, NO. 4, MARCH 1987 399

 lli~ 9
(9
t'1~'15
llll
f!
I.I i i P t f IrtV}
I (3) Inclusion size seems to influence the weld metal mi-
t fJil/-
t"~ll $
&l
'1!
l.I
L
i~P[T tlftvj
A II.t
Fig. 1 8 - EDS X-ray spectra from inclusions in a weld produced with the
40 wt pct SiOr20 wt pct MnO-40 wt pct CaFz: (a) at the acicular ferrite,
and (b) at the proeutectoid grain boundary ferrite.
of the presence of the nonmetallic oxide inclusions. Reduc-
ing the weld metal oxygen content, and thus the inclusion
volume fraction, and maintaining the cooling rate constant,
causes the austenite to remain stable at lower temperatures
because of the reduction of the nucleation sites in terms of
amount and size. At low temperatures when these oxide
inclusions are activated, the austenite is transformed to acic-
ular ferrite; however, it appears that in those cases when the
supercooling is not large enough to activate these inclusions
and the bulk hardenability of the weld metal is low, the
inclusions pin the austenite grain boundaries, increasing the
volume of grain boundary interface available for nucleation
of high temperature ferrites.
Looking at this in the context of the flux behavior in terms
of composition and basicity, acidic fluxes generate high
inclusion contents capable of pinning austenite grain bound-
aries, thereby giving a high area fraction of grain boundaries
available as nucleation sites. In contrast, basic fluxes gener-
ate inclusion distributions less effective in pinning grain
400 VOL. 8, NO. 4, MARCH 1987
boundaries, thereby enhancing the overall hardenability of
the weld metal.
The inclusion characterization reveals that characteristic
morphologies, compositions, and size depend not only on
the flux type but also the detailed composition within a
single flux type.
CONCLUSIONS
(1) The nucleation of weld metal ferrite has been directly
related to the oxide inclusions, and indirectly to weld metal
oxygen content.
(2) Flux composition affects the morphology and size of
ILl
the inclusions.
crostructure. Inclusions 0.6 ~m and smaller are located
within the acicular ferrite; inclusions 1 /zm and greater are
found in the proeutectoid grain boundary and polygonal
ferrites. Small inclusions also pin the austenite grain bound-
aries when failed to be activated, thereby increasing the
grain boundary interface available for nucleation of high
temperature ferrites.
ACKNOWLEDGMENTS
The authors acknowledge and appreciate the support of
the University of Illinois Research Board, the Engineering
Foundation, and the donation of materials by Inland Steel
Company.
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