Bonded Fluxes and Fused Fluxes
There are many types of flux core items that are used in the different welding processes and activities. Among all the different types of fluxes that are used in the Sumberged Arc Welding, two types are most widely spread – the fused flux and the bonded flux, each of them having its advantages and disadvantages. Each commercial welder has its preferences based on one’s experience and practice. However, down the page we will explain the characteristics and the advantages of the two types of flux core.
The fused fluxes
When the commercial welders and the industrial welders are making fused fluxes, the raw materials that they are using are dry mixed together, after which they are fused and melted into a liquid state by a very high temperature furnace. When the fusion is complete, the fluxes are then cooled. This can happen by using big chill blocks or by using a stream of water. When the fused fluxes are cooled by the commercial welder, then they are cooled and crushed into particles. There should a great variety of particle sizes that are made to ensure an optimal performance for the different applications.
The advantages of the fused fluxes
The industrial welders will confirm that the non0hygroscopic flux particles are not in the position to absorb the moisture, thus the surface moisture can be eliminated by drying the particles. This can happen in an oven of low temperatures at 300 degrees F for example. The low temperature will dry the condensation on the fused flux particles and will secure them better protection against hydrogen cracking. The flux particles are forming welds that have chemically consistent structure. The recycling of the fused flux particles through the flux recovery systems can be done without losing composition or sizing.
The bonded fluxes
The commercial welders state that the bonded fluxes are manufactured by combining dry ingredients using a liquid binder, for example potassium silicate or sodium silicate, in order to join the ingredients together. The bonded mix is turned into pellets, then the pellets are baked in an oven with low temperature. When the pellets are dry, they are broken by a sieve in order to get the desired size and then they are packed for shipping.
The advantages of the bonded fluxes
The bonded fluxes get deoxidizers which protect them from the mill scale and the rust. To the bonded fluxes can be added alloys, which can improve the mechanical and the chemical properties of the flux. The bonded fluxes can be divided by colors, they offer thicker layers. Their disadvantage is that they absorb moisture and that they can change in composition because of segregation.