RESEARCH ARTICLE INDIAN WELDING JOURNAL Volume 50 No.

4, October 2017

Effect of Activating Flux on Penetration in

ATIG Welding of 316 Stainless Steel
Sagar Roy1, Siladitya Samaddar2, Md. Nasim Uddin3, Aktarul Hoque4, Sagnik Mishra5 and Santanu Das6
Mechanical Engineering Department, Kalyani Govt. Engineering College, Kalyani, West Bengal, India
Email: [email protected], [email protected], [email protected],
4
[email protected], [email protected], [email protected]

DOI : 10.22486/iwj/2017/v50/i4/162275

ABSTRACT
Tungsten inert gas welding is popular in some industries due to the possibility of obtaining good weld bead surface
and high-quality joint without any weld defect. However, compared to many welding processes, shallow
penetration of TIG welding hinders its applicability to weld thick components in one pass, thus the productivity is
relatively low. An increased depth of penetration can be achieved by Activated TIG (ATIG) welding leading to
overall reduction in number of welding passes, and thus increasing productivity. In the present work, attempts
were made to find out the optimum flux mixture of SiO2 and TiO2 from various ratio of mixtures by carrying out
bead-on-plate welding on AISI 316 Stainless Steel specimens. From the obtained experimental data, suitable flux
ratio was tried to find out giving the highest depth of penetration.

Keywords: Welding; GTAW; ATIG welding; Activating flux; Bead-on-plate welding; Bead geometry; Penetration.

1.0 INTRODUCTION high-quality [5]. However, due to the low depth of penetration,
its productivity is low [6]. If current is increased, weld bead
Austenitic stainless steels contain a maximum of 0.15% carbon
becomes too wide to give good penetration [7]. Activated TIG
and a minimum of 16% chromium to have enough corrosion
(ATIG) welding may be practiced to gain higher penetration
resistance. Nickel is added to it to retain austenitic phase at
than TIG welding [6-8]. By employing ATIG, it is possible to
room temperature. It can also include elements like
weld 8-10 mm thick stainless steel plate in only one pass
molybdenum, titanium, niobium, copper, etc. [1]. These steels
without any edge preparation [9,10]. This is done by coating
offer high corrosion and impact resistance at a low
the faying surface by a thin layer of activating flux before
temperature. Because of these properties, they are employed
welding [11,12]. Some oxides, chlorides and fluorides are used
in marine components, chemical plants, etc. Welding is done to
as the activating flux. Acetone, ethanol or similar solvent is
fabricate different structures in these applications [1,2].
used to produce a slurry of these. The flux tries to constrict the
Tungsten inert gas (TIG) welding, or Gas tungsten arc welding arc thereby making hike in current density and arc force on the
(GTAW), uses [3,4] a non-consumable tungsten electrode and weld pool [8,13]. The favourable effect of activating flux in TIG
an inert shielding gas, generally argon, is applied to protect the welding was first reported by EO Paton Institute of Electric
weld from atmospheric contamination. TIG is usually employed Welding, former Soviet Union, way back in 1960s. About three
to weld thin stainless steel and non-ferrous components with times enhancement in penetration was demonstrated with the

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Roy et al. : Effect of Activating Flux on Penetration in ATIG Welding of 316 Stainless Steel

use of a thin layer of flux [14-17]. Activating fluxes by now are corrosion behaviour of austenitic stainless steel in A-TIG
commercially used in different applications for welding Mn Welding using those flux materials, and concluded that
steels, Cr-Mo steels, nickel-based alloys, etc. [3]. increased content of oxide flux resulted in more corrosion
resistance.
Thus, ATIG welding is not very new, but there is lacking of well-
accepted theoretical explanation behind this process of In this experimental investigation, ATIG welding is done on
activation. In this paragraph, some models are reviewed to austenitic stainless steel specimens using different fluxes. The
explain the ATIG welding as thought of by some researchers in extent of penetration is observed for all the experimental runs
the past. Simonik proposed a model while experimenting on to evaluate the condition to achieve the highest penetration
titanium with flux made up of calcium and aluminium fluorides within the domain of this investigation.
that considered major role of vaporized ions of flux generated
by arc heating for this activation. He assumed ions at the arc
periphery to have lower mobility than that at the central region, 2.0 DETAIL OF THE EXPERIMENTAL WORK
and this might lead to a hike in current density at the centre of AISI 316 stainless steel is used as the base material. It is a
the arc. On the other hand, Heiple and Roper assumed molybdenum-alloy steel, and is a common austenite stainless
occurrence of reversed Marangoni flow for this activation. In steel grade. It is often preferred for the use in marine
this model, the flux is assumed to revert the sign of environment because of its greater resistance to corrosion
temperature coefficient of surface tension from negative to than other grades of steels without molybdenum. The
positive, and it changes the direction of surface Marangoni flow composition of the base plate is shown in Table 1. Stainless
from outward to inward direction. This inward flow is steel plates are cut into samples having the size of 382mm x
transformed into a downward direction at the hot centre of the 317mm x 5mm with the help of an abrasive cutter. Edges of the
weld, thereby increasing heat transfer due to convection and plates are machined, and before welding, surfaces of the
melting of the metal in a downward direction. Savitskii and specimen are thoroughly cleaned with wire brush and acetone
Leskov postulated a model based on surface tension reducing to ensure cleanliness.
effect of the flux that causes high arc pressure creating deep
It is known from previous research works that some metallic
depression inside weld pool and resulting in high depth of
and non-metallic oxides, etc. work as a good activating flux in
penetration. Arc constriction model considered [18-20]
GTAW process. SiO2 and TiO2 are reported to be some of such
electrical insulating effect of the flux. Flux covered surface
activating fluxes. However, to explore the activation effect of
offers high electrical resistance, reduces size of arc spot, and
some flux mixtures, in the present work, three different
leads to deep penetration.
proportions of SiO2 and TiO2 are considered. Detail of flux used
ATIG process mainly focuses on increasing depth of in this work is given in Table 2. First set of experiments is done
penetration of weld bead. Again, reduction in weld bead has a without using any flux. Subsequent 2nd, 3rd and 4th sets of
significant role in good welding because large size of bead experiments are performed using different flux mixtures.
width results in a wide heat affected zone (HAZ). Therefore, According to the selected flux composition, SiO2 and TiO2 are
analysis of both depth of penetration and bead width is having taken to the required proportion, and the slurry is made by
remarkable significance [21, 22]. In another work, effect of mixing the flux material in acetone. A thin layer of activating
different oxide flux materials on the depth of penetration was flux is applied with a brush on the surface, on which the bead is
investigated [23] during A-TIG Welding of austenitic stainless to be made.
steels. The authors also studied the microstructure and

Table 1: Chemical composition of base metal (wt %)

Material C Mn Si S P Cr Ni Mo N Fe

AISI 316 0.027 1.11 0.434 0.0045 0.017 16.77 10.03 2.03 0.044 Balance

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 INDIAN WELDING JOURNAL Volume 50 No. 4, October 2017

Table 2 : Detail of Flux used Table 3 : Welding Parameters used

Sl. No. Proportion of Flux (SiO2:TiO2) Used Welding speed 120mm/min

1 No flux used Current used Pulsed DCSP, 40% duty cycle
2 1:1 Welding current 90A, 105A, 120A
3 4:1 DC pulse frequency 60Hz, 140Hz, 240Hz
4 1:4 Shielding gas 100% argon,
flow rate: 15 litre/min

Bead-on-plate welding without any filler material, that is, Electrode 3 mm diameter, thoriated
autogenous welding, is performed with the flux as mentioned tungsten
in Table 2. The welding passes were made with an automatic Electrode tip distance 5 mm
feeding vehicle on which the weld torch is mounted and moved
at a constant speed. Welding parameters employed in this
sectional area of weld bead are found out using a software
project are given in Table 3.
programme. Bead cross sectional area corresponds to melting
The base plate with bead deposit is cut along its cross section efficiency of welding.
using an abrasive cutter. The cut surface was ground with the
help of a belt grinder / polisher, disc grinder / polisher. It is
polished using fine grade emery papers of rough to finer ones 3.0 RESULTS AND DISCUSSION
(180 to 1200 grade). The specimens are then polished on Results of common TIG welding without using a flux to make
velvet cloth polisher with the help of alumina paste. The bead-on-plate welds are shown in Table 4. In these tests, a
etchant solution is prepared by mixing 0.5 gm CuCl2 and 10 ml maximum penetration of 2.174mm is found at experimental
C2H5OH (99%) in 10 ml HCL (40% v/v) and is applied on the run No. 4. A low penetration of 1.284mm is obtained in the
polished surface of the specimen. After etching, specimens are experimental run No.6. At a low pulse frequency of 60Hz
observed under microscope for determining the bead corresponding to experimental run No.7, no measurable
geometry. Depth of penetration, bead width and cross- penetration is reported.

Table 4 : Results of TIG welding without using a flux

Sl. Weld DC Pulse Weld Heat Depth of Width of Aspect Area of Weld
No. Current frequency Voltage Input penetration weld bead Ratio bead cross
(A) (Hz) (V) (kJ/mm) (mm) (mm) Section (mm2)

1 90 60 17 0.57 2.046 6.75 0.303 8.807

2 90 140 15 0.57 1.875 7.43 0.25 8.062

3 90 240 12 0.405 1.701 5.80 0.29 7.25

4 105 60 13 0.51 2.174 8.30 0.26 13.69

5 105 140 15 0.59 1.404 8.05 0.17 7.002

6 105 240 16 0.63 1.284 9.63 0.13 4.574

7 120 60 14.5 0.65 ---- ---- ---- ----

8 120 140 15.2 0.68 1.477 8.47 0.17 9.484

9 120 240 14.8 0.66 1.701 8.51 0.10 ----

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Roy et al. : Effect of Activating Flux on Penetration in ATIG Welding of 316 Stainless Steel

Table 5 : Results of ATIG welding using a flux of SiO2 and TiO2 mixture in 1:1 ratio

Sl. Weld Weld DC Pulse Heat Depth of Width of Aspect Area of Weld
No. Current Voltage frequency Input penetration weld bead Ratio bead cross
(A) (V) (Hz) (kJ/mm) (mm) (mm) Section (mm2)

1 90 17.5 60 0.59 2.695 4.50 0.598 10.75

2 90 17.2 140 0.58 2.182 5.853 0.372 9.899

3 90 17.0 240 0.57 2.423 6.050 0.40 10.801

4 105 18.1 60 0.71 3.955 7.18 0.55 21.853

5 105 17.8 140 0.70 4.204 6.61 0.636 21.367

6 105 17.6 240 0.69 3.875 7.22 0.537 18.297

7 120 18.5 60 0.83 2.752 9.15 0.30 21.177

8 120 17.9 140 0.80 Full 7.77 0.64 25.556

9 120 19.8 240 0.89 3.24 13.60 0.23 22.933

Results of ATIG Welding with a flux of SiO2 and TiO2 mixture in Results of ATIG Welding with a flux of SiO2 and TiO2 mixture in
1:1 ratio are presented in Table 5. Compared to common TIG 1:4 ratio are presented in Table 7. Compared to common TIG
welding without using a flux, this flux mixture of SiO2 and TiO2 welding without using a flux, this flux of SiO2 and TiO2 mixture
gives remarkably higher penetration. While the maximum in 1:4 ratio gives lesser penetration in some cases and shows
penetration reported in TIG welding is 2.174mm, in this ATIG slightly higher penetration mainly at the high weld current of
welding with equal proportion mixture of silica and titania, the 120A with 0.63kJ/mm heat input. Maximum penetration seen
minimum penetration is seen to be 2.182mm at a low weld in this ATIG welding is only 2.884mm. Thus, this flux mixture
current with a low heat input of 0.58 kJ/mm (experiment Sl. does not give much effect to raise weld bead penetration.
No. 2) and in experimental run No.8 with high weld current and
Variation of depth of penetration with welding current is shown
medium pulse frequency with the corresponding high heat
in Fig.1 through Fig.3. From these figures, it can be observed
input of 0.80 kJ/mm, full penetration of 5mm is noticed.
that the overall change in penetration with current is very low
Therefore, clear indication of large-scale effectiveness of the
for common TIG welding. On the other hand, with the increase
activating flux is observed.
in current, penetration of ATIG welding using 1:1 and 4:1
Results of ATIG Welding with a flux of SiO2 and TiO2 mixture in (SiO2:TiO2) flux increases sharply. In case of ATIG welding
4:1 ratio are presented in Table 6. Compared to common TIG using 1:1 flux mixture of silica and titania, best result is
welding without using a flux, this flux mixture gives higher observed at medium frequency of 140Hz (Fig.2). For welding
penetration on the whole. While the maximum penetration with 4:1 flux mixture, the penetration increases consistently
reported in TIG welding is 2.174mm, in this ATIG welding with with current at all frequencies and at high current deep
4:1 ratio of silica and titania mixture, the maximum penetration penetration of about 4mm is observed. In case of ATIG welding
is seen to be as high as 4.137mm corresponding to using 1:4 flux mixture of silica and titania, penetration is poor
experimental run No. 9 with 120A weld current, high pulse at low and medium frequency (Fig.1 and Fig.2). Only when
frequency of 240Hz and heat input of 0.58. This flux mixture current is changed to high value, increase in penetration is
indicates its effectiveness over common TIG welding; however, observed.
penetration obtained in this experiment is on the whole lesser
than that obtained in ATIG welding using equal proportion of
the two flux materials used.

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 INDIAN WELDING JOURNAL Volume 50 No. 4, October 2017

Table 6 : Results of ATIG welding using a flux of SiO2 and TiO2 mixture in 4:1 ratio

Sl. Weld Weld DC Pulse Heat Depth of Width of Aspect Area of Weld
No. Current Voltage frequency Input penetration weld bead Ratio bead cross
(A) (V) (Hz) (kJ/mm) (mm) (mm) Section (mm2)

1 90 12.2 60 0.41 0.723 5.089 0.14 2.509

2 90 12.1 140 0.408 1.035 5.077 0.20 4.204

3 90 11.5 240 0.38 1.838 5.306 0.34 6.607

4 105 12.5 60 0.49 1.773 5.820 0.30 7.557

5 105 12.6 140 0.49 1.685 6.23 0.27 8.814

6 105 11.8 240 0.46 1.934 8.37 0.23 13.69

7 120 12.3 60 0.55 3.683 7.62 0.48 19.041

8 120 12.5 140 0.56 3.979 7.11 0.55 19.116

9 120 13 240 0.58 4.137 8.12 0.50 22.091

Table 7 : Results of ATIG welding using a flux of SiO2 and TiO2 mixture in 1:4 ratio

Sl. Weld Weld DC Pulse Heat Depth of Width of Aspect Area of Weld
No. Current Voltage frequency Input penetration weld bead Ratio bead cross
(A) (V) (Hz) (kJ/mm) (mm) (mm) Section (mm2)

1 90 11.4 60 0.38 0.906 6.05 0.149 4.448

2 90 12 140 0.40 0.818 4.894 0.167 3.350

3 90 13.1 240 0.44 0.971 5.804 0.167 4.467

4 105 11.8 60 0.46 1.243 6.492 0.191 5.546

5 105 13 140 0.51 0.818 5.787 0.141 3.298

6 105 13.7 240 0.53 1.067 6.439 0.167 5.199

7 120 13 60 0.58 1.620 7.76 0.209 10.619

8 120 13.5 140 0.60 1.388 7.19 0.193 17.550

9 120 14.1 240 0.63 2.884 6.411 0.449 18.629

Fig.1 : Plot of variation of depth of penetration with Fig.2 : Plot of variation of depth of penetration with
welding current at 60Hz pulse frequency in TIG and welding current at 140Hz pulse frequency
ATIG welding processes in TIG and ATIG welding processes

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Roy et al. : Effect of Activating Flux on Penetration in ATIG Welding of 316 Stainless Steel

Fig.3 : Plot of variation of depth of penetration Fig.4 : Plot of variation of width of weld bead
with welding current at 240Hz pulse frequency with welding current at 60Hz pulse frequency
in TIG and ATIG welding processes in TIG and ATIG welding processes

Variation of weld bead width with current is shown from Fig. 4

to Fig. 6. From these plots, it is evident that ATIG welding with
flux generally produces a narrow weld bead compared to
common TIG welding without flux. Among the used flux
mixtures, ATIG welding with 1:1 silica and titania mixture has
produced wider weld bead compared to flux mixture with 4:1
and 1:4 of silica and titania. Overall, both 4:1 and 1:4 flux
mixtures have shown quite narrow weld bead. For ATIG
welding using 1:4 flux mixture, at high frequency, bead width
almost remains constant with the increase in current (Fig.6).

Variation of aspect ratio with current is shown from Fig. 7 to

Fig. 9. A high aspect ratio is desirable as it is a characteristic of
an increased energy density of the heat source in welding. With Fig.5 : Plot of variation of width of weld bead with
an increase in the density of heat input, overall heat require- welding current at 140Hz pulse frequency
in TIG and ATIG welding processes
ment per unit length of welding decreases. From Fig. 7 to
Fig. 9, it is seen that for common TIG welding aspect ratio is
generally low. As current is increased, aspect ratio generally
falls to a low value (≤0.2 at high current). ATIG welding with
1:1 SiO2 and TiO2 flux mixture has shown high value of aspect
ratio at low and medium current. For ATIG welding employing a
flux of 4:1 mixture of silica and titania, the aspect ratio at low
current becomes low, but as current is increased, the value of
aspect ratio increases rapidly and reaches a high value of about
0.5 at high current. This indicates that with increasing current,
the rate of increase in penetration is more compared to the rate
of increase in bead width. The aspect ratio for ATIG welding
with 1:4 flux mixture is, on the whole, quite low compared to
the other welding processes tested in this work.
Fig.6 : Plot of variation of width of weld bead
with welding current at 240Hz pulse frequency
in TIG and ATIG welding processes

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 INDIAN WELDING JOURNAL Volume 50 No. 4, October 2017

From the above discussion, it can be concluded that common

TIG welding without a flux produced a sallow and wide weld
bead. In TIG welding, the surface Marangoni flow of molten
metal is from inward to outward direction. The arc is also
spread over a wider region. Thus the arc force on the molten
metal pool is low. Introduction of flux can change the direction
of temperature coefficient of surface tension from negative to
positive, which, in turn, changes the direction of surface
Marangoni flow from outwards to inwards. It also constricts the
arc thereby increasing arc force on the pool of molten metal.
Thus a deep and narrow weld bead is obtained in ATIG welding
using fluxes.
Fig.7 : Plot of variation of aspect ratio with
welding current at 60Hz pulse frequency In this experiment, the effect of different fluxes on penetration
in TIG and ATIG welding processes is found to vary largely. It can be observed that SiO2 flux causes
deeper penetration compared to TiO2 flux. This can be
explained by comparing the properties of these two oxides. For
SiO2 flux, the dominating factor in increasing the penetration
seems to be constriction of arc. Silica has a lower boiling point
(2230oC) compared to titania (2972oC). Under intense heat of
the arc, silica easily vaporizes and causes redistribution of
charge career in the arc column. Silicon being more electro-
negative compared to titanium, can absorb electrons in the
periphery region of the arc easily. In this region, the
temperature is sufficiently low to form negative ion. The ions in
the periphery region are less mobile compared to the high
energy electrons of the central region of the arc. Thus, the arc
gets constricted and a higher arc force is exerted on the molten
Fig.8 : Plot of variation of aspect ratio metal pool. This effectively increases the depth of penetration
with welding current at 140Hz pulse frequency of welding using SiO2 flux. Additionally, SiO2 has more
in TIG and ATIG welding processes
resistance value compared to TiO2. So the arc is more restricted
at the anode root for ATIG welding using SiO2 flux. This also
causes SiO2 flux welding to achieve greater penetration
compared to TiO2 flux welding.

Application of flux mostly produces a narrow, deep weld bead

compared to that at conventional TIG welding. Typical bead
profiles for TIG and ATIG with different flux mixtures are shown
in Fig.10 and Fig.11 corresponding to weld current of 105A
and 120A under 140Hz DC pulse frequency.

An inferior weld bead appearance is produced by the use of

flux compared to that seen in conventional TIG welding. The
surface slag residue is left out after welding that needs be
removed after welding. Increased percentage of SiO2 in the

Fig.9 : Plot of variation of aspect ratio with flux mixture improves overall bead appearance compared to
welding current at 240Hz pulse frequency that using TiO2.
in TIG and ATIG welding processes

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Roy et al. : Effect of Activating Flux on Penetration in ATIG Welding of 316 Stainless Steel

Fig.10 : Typical view of weld beads at 105A current and 140Hzpulse frequency
[Left to right: TIG welding, ATIG welding with SiO2:TiO2 flux mixture of 1:1, 4:1 and 1:4]

Fig.11 : Typical view of weld beads at 120A current and 140Hz pulse frequency
[Left to right: TIG welding, ATIG welding with SiO2:TiO2 flux mixture of 1:1, 4:1 and 1:4]

In the present work on welding of 316 stainless steel, · In this work, it is found that using the flux, depth of
conventional TIG produces wider and shallower weld bead penetration can be increased greatly. Study on different
profile than ATIG welding on the whole. Bead width is low in flux mixtures of SiO2 and TiO2 reveals that SiO2 flux has
TiO2 rich flux mixture. However, TiO2 rich flux mixture has more influence on depth of penetration.
increased the depth of penetration by 23.59% on an average
· Large increase in depth of penetration is obtained over
compared to conventional TIG at 120 A current. Whereas SiO2
conventional TIG welding when a flux mixture of SiO2 and
dominant flux mixture improved the depth of penetration by
TiO2 with a ratio of 4:1 and 1:1 are used.
147.5% on an average compared to conventional TIG at 120 A
current and Flux mixture with equal proportion of SiO2 and TiO2 · Full penetration of 5mm is achieved flats at 120A current,
improved the penetration by 130.5% on an average at 120 A 17.9V voltage and 140Hz condition when equal
current. For each type of flux mixture, there is sharp increase of proportion of SiO2 and TiO2 are used.
depth of penetration with the increase of current. However, for · Application of flux reduces bead appearance of ATIG
conventional TIG welding, depth of penetration shows almost weldment to some extent.
no change with an increase of current after current reaches a
· Suitable activated flux improves depth of penetration
certain point. Further increase in current tends to increase
substantially in ATIG welding. Hence, ATIG has the
weld bead width.
possibility of wide practical use in industry for its
Full penetration of 5mm is achieved at 0.80 kJ/mm heat input improved productivity and quality.
with flux mixtures of 1:1 of SiO2:TiO2 at 120 A current.
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