Hybrid Welding of SA516 Gr70 Carbon Steel Material Using Solid and Cored Wires

Researchers are working on hybrid welds, means application of two different processes one after another. Hybrid weld applications using non consumable arc welding processes, such as Gas Tungsten Arc Welding (GTAW), Plasma Arc welding (PAW) and combination of both mean PAW for the ischolar_main run and GTAW for the filler and cap passes. Conventionally ischolar_main run is filled with the GTAW process because of the excellent weld metal properties and subsequent filler passes with SMAW, SAW or GMAW processes, depending on the size and nature of the job. In the present investigation hybrid concept has been applied to consumable arc welding processes like GMAW, FCAW&MCAW. Metal cored wires 30-35 % costlier than solid wire. Especially for heavy section filler metal requirements increases with increase in plate thickness and process become more costly than normal GMAW.

In the present investigation, 10 mm thick SA516Gr70 steel plate welded using three different consumables includes solid wire (ER70S-6), flux cored wire (E71T-1C) and metal cored wire (E70C-6M) of 1.2mm in size. To weld 10 mm thick plate at 60 degree V-groove, it required two passes, one at the ischolar_main and followed by filler pass. Carbon steel plate SA516Gr70 welded under different hybrid modes combinations. Effect of different hybrid welds welded with solid wire, flux cored and metal cored wire consumables on mechanical and metallurgical properties has been studied, keeping welding variable constant. It was found that hybrid combinations of solid and flux cored wire yield better mechanical properties compared to solid-solid and solid-metal cored wire.