team photo

Figure 1
project photo

Figure 2
project photo


Team 1

Team Members

Faculty Advisor

Kathryn Breen
Benjamin Ellery

Dr. Harold Brody

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Flux Core Material Evaluation for Improved Welding of Duplex Stainless Steel

General Dynamic Electric Boat (EB) is investigating the use of the flux cored arc welding (FCAW) process for duplex stainless steel (DSS) applications. A flux core electrode is made up of metal sheath containing alloying elements, fluxing agents, deoxidizers and arc enhancers. Despite being manufactured to the same specifications flux core electrodes from different brands can operate differently, because each company has its own formula of the aforementioned constituents for creating these products. Currently, EB has identified two promising electrodes and has recognized that, at the micro-structural level inclusion content may have an effect over the mechanical properties observed. The goal of this project is to characterize the inclusions present in the flux-cored welds and build and an understanding of how their presence affects the mechanical properties and performance in application, with the intention of identifying a superior electrode. Characterization of inclusion content using scanning electron microscopy and energy dispersive x-ray spectroscopy was compared to tensile testing, ferrite count, and Charpy V-notch impact testing data of weld samples in order to affirm the impact of electrode composition and cooling rate on weld mechanical properties.