The effect of different heat inputs of 1.45 kJ/mm, 1.78 kJ/mm and 2.31 kJ/mm on the microstructure and mechanical properties of deposited metals of the self-developed AWS A5.28 E120C-K4 high strength steel flux-cored wire was studied by optical microscope, scanning electron microscope and mechanical property test. With the increase in heat input, the results showed that the microstructure of deposited metals became coarse. Acicular ferrite increased at first and then decreased, granular bainite increased and degenerated upper bainite and martensite decreased slightly. Under the low heat input of 1.45 kJ/mm, the cooling rate was fast and the element diffusion was uneven, which caused composition segregation and easy to form large size inclusions SiO₂-TiC-CeAlO₃ with weak binding to the matrix. Under the middle heat input of 1.78 kJ/mm, the composite rare earth inclusions in dimples were mainly TiC-CeAlO₃. The dimples were small and uniformly distributed, and the dimple fracture mainly depended on the wall-breaking connection between medium-sized dimples rather than an intermediate media. Under the high heat input of 2.31 kJ/mm, SiO₂ was easy to adhere to high melting point Al₂O₃ oxides to form irregular composite inclusions. Such irregular inclusions do not need to absorb too much energy to form necking. Finally, the integrated effects of microstructure and inclusions resulted in the optimum mechanical properties of deposited metals with a heat input of 1.78 kJ/mm, which was a tensile strength of 793 MPa and an average impact toughness at −40 °C of 56 J.

The effect of rare earth Pr6O11 on the microstructure and mechanical properties of high-strength steel weld metal was investigated by optical microscopy, scanning electron microscopy and mechanical testing. Three different contents of Pr6O11 were added to the flux-cored wires. The results showed that the addition of 1% Pr6O11 can promote the refinement and spheroidization of inclusions, refine the grains, form acicular ferrites, and significantly improve the toughness of weld metal. The addition of Pr6O11 promoted the formation of rare earth composite inclusions and acicular ferrites in the weld metal, refined the lath microstructure, inhibited the formation of martensite and bainite. The crack formation mode changed from the boundary cracking of the bainite clusters caused by the surface shear stress to the surface shear stress-induced decohesion of inclusion. However, excessive addition of Pr6O11 will reduce the number of inclusion nucleation and deteriorate the mechanical properties. The wire No.2 with 1% Pr6O11 had the good comprehensive mechanical properties, and the corresponding values were 835MPa of tensile strength and 72 J of impact toughness. These findings suggest that the control of Pr6O11 can be an effective way to improve the impact toughness of weld metal.