Study of the Effects of Hardfacing Modes Carried out by FCAW-S with Exothermic Addition of MnO<sub>2</sub>-Al on Non-Metallic Inclusions, Grain Size, Microstructure and Mechanical Properties
This paper investigates self-shielded flux-cored wires with an exothermic MnO<sub>2</sub>-Al addition and the effect of hardfacing modes on the deposited alloy of the Fe-C-Mn system for the first time. Additionally, the paper proposes a new experimental research methodology using an orth...
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MDPI AG
2025-06-01
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| Series: | Eng |
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| Online Access: | https://www.mdpi.com/2673-4117/6/6/125 |
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| author | Bohdan Trembach Illia Trembach Aleksandr Grin Nataliia Makarenko Olha Babych Sergey Knyazev Yuliia Musairova Michal Krbata Oleksii Balenko Oleh Vorobiov Anatoliy Panchenko |
| author_facet | Bohdan Trembach Illia Trembach Aleksandr Grin Nataliia Makarenko Olha Babych Sergey Knyazev Yuliia Musairova Michal Krbata Oleksii Balenko Oleh Vorobiov Anatoliy Panchenko |
| author_sort | Bohdan Trembach |
| collection | DOAJ |
| description | This paper investigates self-shielded flux-cored wires with an exothermic MnO<sub>2</sub>-Al addition and the effect of hardfacing modes on the deposited alloy of the Fe-C-Mn system for the first time. Additionally, the paper proposes a new experimental research methodology using an orthogonal experimental design with nine experiments and three levels. At the first stage, it is proposed to use the Taguchi plan (L9) method to find the most significant variables. At the second stage, for the development of a mathematical model and optimization, a factorial design is recommended. The studied parameters of the hardfacing mode were travel speed (<i>TS</i>), set voltage on the power source (<i>U<sub>set</sub></i>), contact tip to work distance (<i>CTWD</i>), and wire feed speed (<i>WFS</i>). The following parameters were studied: welding thermal cycle parameters, microstructure, grain size, non-metallic inclusions, and mechanical properties. The results of the analysis showed that the listed parameters of the hardfacing modes have a different effect on the characteristics of the hardfacing process with self-shielded flux-cored wires with an exothermic addition in the filler. It was determined that for flux-cored wires with an exothermic addition, the size of the deposited metal grain size is most affected by the contact tip to work distance (<i>CTWD</i>). The research results showed that the travel speed (<i>TS</i>) had the main influence on the thermal cycle parameters (heat input, cooling time) and hardness. The analysis of the deposited metal samples showed that an increase in the travel speed had a negative impact on the number of non-metallic inclusions (NMIs) in the deposited metal. While the size of NMIs was influenced by the wire feed speed and the set voltage on the power source. |
| format | Article |
| id | doaj-art-fd01bb5c4c594fd7913d5fbf5c7be475 |
| institution | Kabale University |
| issn | 2673-4117 |
| language | English |
| publishDate | 2025-06-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Eng |
| spelling | doaj-art-fd01bb5c4c594fd7913d5fbf5c7be4752025-08-20T03:27:26ZengMDPI AGEng2673-41172025-06-016612510.3390/eng6060125Study of the Effects of Hardfacing Modes Carried out by FCAW-S with Exothermic Addition of MnO<sub>2</sub>-Al on Non-Metallic Inclusions, Grain Size, Microstructure and Mechanical PropertiesBohdan Trembach0Illia Trembach1Aleksandr Grin2Nataliia Makarenko3Olha Babych4Sergey Knyazev5Yuliia Musairova6Michal Krbata7Oleksii Balenko8Oleh Vorobiov9Anatoliy Panchenko10Rappresentanze Industriali M&C Division doo, 52000 Pazin, CroatiaWelding Technology Department, Donbas State Engineering Academy, 84313 Kramatorsk, UkraineWelding Technology Department, Donbas State Engineering Academy, 84313 Kramatorsk, UkraineWelding Technology Department, Donbas State Engineering Academy, 84313 Kramatorsk, UkraineScientific Research Laboratory, Ivan Kozhedub Kharkiv National Air Force University, 61045 Kharkiv, UkraineDepartment of Materials Science, National Technical University “Kharkiv Polytechnic Institute”, 61000 Kharkiv, UkraineScientific Research Laboratory, Ivan Kozhedub Kharkiv National Air Force University, 61045 Kharkiv, UkraineFaculty of Special Technology, Alexander Dubcek University of Trenčín, 911 06 Trenčín, SlovakiaDepartment of Computer Engineering and Programming, National Technical University “Kharkiv Polytechnic Institute”, 61000 Kharkiv, UkraineScientific Research Laboratory, Ivan Kozhedub Kharkiv National Air Force University, 61045 Kharkiv, UkraineScientific Research Laboratory, Ivan Kozhedub Kharkiv National Air Force University, 61045 Kharkiv, UkraineThis paper investigates self-shielded flux-cored wires with an exothermic MnO<sub>2</sub>-Al addition and the effect of hardfacing modes on the deposited alloy of the Fe-C-Mn system for the first time. Additionally, the paper proposes a new experimental research methodology using an orthogonal experimental design with nine experiments and three levels. At the first stage, it is proposed to use the Taguchi plan (L9) method to find the most significant variables. At the second stage, for the development of a mathematical model and optimization, a factorial design is recommended. The studied parameters of the hardfacing mode were travel speed (<i>TS</i>), set voltage on the power source (<i>U<sub>set</sub></i>), contact tip to work distance (<i>CTWD</i>), and wire feed speed (<i>WFS</i>). The following parameters were studied: welding thermal cycle parameters, microstructure, grain size, non-metallic inclusions, and mechanical properties. The results of the analysis showed that the listed parameters of the hardfacing modes have a different effect on the characteristics of the hardfacing process with self-shielded flux-cored wires with an exothermic addition in the filler. It was determined that for flux-cored wires with an exothermic addition, the size of the deposited metal grain size is most affected by the contact tip to work distance (<i>CTWD</i>). The research results showed that the travel speed (<i>TS</i>) had the main influence on the thermal cycle parameters (heat input, cooling time) and hardness. The analysis of the deposited metal samples showed that an increase in the travel speed had a negative impact on the number of non-metallic inclusions (NMIs) in the deposited metal. While the size of NMIs was influenced by the wire feed speed and the set voltage on the power source.https://www.mdpi.com/2673-4117/6/6/125Hadfield manganese steelself-shielded flux-cored wireexothermic additionthermal cycle parametersheat inputaustenitic microstructure |
| spellingShingle | Bohdan Trembach Illia Trembach Aleksandr Grin Nataliia Makarenko Olha Babych Sergey Knyazev Yuliia Musairova Michal Krbata Oleksii Balenko Oleh Vorobiov Anatoliy Panchenko Study of the Effects of Hardfacing Modes Carried out by FCAW-S with Exothermic Addition of MnO<sub>2</sub>-Al on Non-Metallic Inclusions, Grain Size, Microstructure and Mechanical Properties Eng Hadfield manganese steel self-shielded flux-cored wire exothermic addition thermal cycle parameters heat input austenitic microstructure |
| title | Study of the Effects of Hardfacing Modes Carried out by FCAW-S with Exothermic Addition of MnO<sub>2</sub>-Al on Non-Metallic Inclusions, Grain Size, Microstructure and Mechanical Properties |
| title_full | Study of the Effects of Hardfacing Modes Carried out by FCAW-S with Exothermic Addition of MnO<sub>2</sub>-Al on Non-Metallic Inclusions, Grain Size, Microstructure and Mechanical Properties |
| title_fullStr | Study of the Effects of Hardfacing Modes Carried out by FCAW-S with Exothermic Addition of MnO<sub>2</sub>-Al on Non-Metallic Inclusions, Grain Size, Microstructure and Mechanical Properties |
| title_full_unstemmed | Study of the Effects of Hardfacing Modes Carried out by FCAW-S with Exothermic Addition of MnO<sub>2</sub>-Al on Non-Metallic Inclusions, Grain Size, Microstructure and Mechanical Properties |
| title_short | Study of the Effects of Hardfacing Modes Carried out by FCAW-S with Exothermic Addition of MnO<sub>2</sub>-Al on Non-Metallic Inclusions, Grain Size, Microstructure and Mechanical Properties |
| title_sort | study of the effects of hardfacing modes carried out by fcaw s with exothermic addition of mno sub 2 sub al on non metallic inclusions grain size microstructure and mechanical properties |
| topic | Hadfield manganese steel self-shielded flux-cored wire exothermic addition thermal cycle parameters heat input austenitic microstructure |
| url | https://www.mdpi.com/2673-4117/6/6/125 |
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