Effect of flux cored arc welding process parameters on bead geometry in super duplex stainless steel claddings

•Weld cladding of super duplex stainless was simulated using response surface models.•Heat input during the experimental runs was maintained between 0.5 and 1.5 kJ/mm.•The use bead contact angle is to reduce percentage overlap in multi pass surfacing.•Reinforcement form factor and contact angle exhibits inverse relationship each other.

The welding heat input plays a significant role in determining the microstructure and composition of the super duplex stainless steel cladding. The welding process is represented in the form of mathematical models developed using response surface methodology. The models were then used to predict the weld bead characteristics with reasonable accuracy. In this work, the models were developed to relate the identified important process parameters like welding voltage, wire feed rate, welding speed, nozzle to plate distance and welding gun angle with bead geometry. The models found to satisfy the adequacy requirements. It was found that reinforcement form factor was influenced by the factors arc length, torch travel speed, melting rate and resistance heating of the electrode. In the same way penetration form factor is influenced by the arc length, torch travel speed and arc force at the weld puddle. Contact angle influenced by the melting rate and resistance heating of the electrode.

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