The purpose of this study is to investigate the transfer behavior of oxygen during the submerged arc welding process using CaF₂-SiO₂-CaO fluxes. In contrast to previous research that only focused on the final oxygen content in the final weld metal, this study introduces two new parameters, Δ_dO and Δ_wO, to quantify the oxygen transfer in essential regions: the droplet and weld pool zones, respectively. The transfer behavior of oxygen is analyzed by using typical Multi-Zone and equilibrium models. The results indicate that the Multi-Zone model is capable of capturing the metallurgical processes of oxidation and subsequent reduction during the submerged arc welding process. Moreover, the Multi-Zone model demonstrates superior predictive accuracy in estimating oxygen content in the metal compared to the equilibrium model. Based on measured values and metallurgical data, this article analyzes the oxygen transfer mechanism and non-equilibrium state in the submerged arc welding process from both thermodynamic and kinetic perspectives. Then, scientific hypotheses previously put forward are validated and discussed, which may offer valuable insights and practical guidance for flux design.

Welding current is an essential parameter for submerged arc welding process. In submerged arc welding, the enormous heat generated by the current promotes the decomposition of the oxides in the flux, releasing oxygen and increasing the oxygen level in the metal, which further affects the microstructure and mechanical properties of the weld joint. Although previous studies have developed various models to evaluate oxygen content, the thermodynamic mechanism by which current influences oxygen levels in metal remains inadequately understood. This study integrates CALPHAD technology with welding thermodynamics to predict and simulate the impact of the welding current on oxygen content in metals. By combining experimental data with thermodynamic modeling, the research investigates how different current settings affect oxygen content in the metal across various welding zones, specifically when using CaO-Al₂O₃ fluxes with low and high basicity indices for the welding of typical carbon steel. This study selected two current values, 300 A and 600 A, for modeling analyses of the welding process, along with two typical fluxes with basicity indices of 1.6 and 0.4. The results indicate that the proposed method outperforms the BI model and can predict the metallurgical effects of current on oxygen content in the droplet and molten pool zones. The thermodynamic mechanisms that govern the metal oxygen level are also evaluated. These findings aim to enhance the understanding of the thermodynamic mechanism that governs oxygen behavior under different current conditions, thereby contributing to the optimization of submerged arc welding process.

In submerged arc welding, evaluating elemental transfer behaviors is critical for selecting and designing welding materials. Accurate assessment of O, Si, and Mn transfer behavior is essential for ensuring process quality, particularly when silicon-manganese fluxes are applied. Traditional quantification methods, however, focus only on chemical reactions in the weld pool zone, potentially overlooking the cross-zone elemental transfer behavior and leading to significant predictive inaccuracies. This study investigates the CaO-SiO₂-MnO flux, a prevalent silicon-manganese flux, focusing on O, Si, and Mn, which exhibit notable transfer behaviors of O, Si, and Mn. By employing a multi-zone approach and integrating various scientific principles, the research aims to improve the accuracy of predicting elemental transfer behaviors and deepen the understanding of the metallurgical processes in submerged arc welding when silicon-manganese fluxes are employed. The study proposes strategic enhancements to traditional quantification methods, which may offer valuable insights for the improvement of industry standards. This study demonstrates that considering only the local thermodynamic equilibrium of the weld pool zone when quantifying the transfer behavior of elements may lead to predictive errors, especially for easily evaporating metallic elements. By incorporating a cross-zone assessment for submerged arc welding process, i.e., introducing new quantifying parameters (Δ_d and Δ_w), the predictive accuracy of the transfer behavior of elements and their cross-zone actions can be enhanced.

This study aims to predict and evaluate the transfer behavior of silicon employing SiO₂-bearing fluxes during submerged arc welding. Unlike previous studies that only focused on chemical reactions in the weld pool zone, this research investigates the elemental behavior of silicon subjected to essential reaction zones in a submerged arc welding process. The proposed method is compared with the traditional thermodynamic equilibrium models, enhancing the understanding of silicon transfer behavior in the submerged arc welding process. It is demonstrated that relying solely on thermodynamics within the weld pool zone is inadequate for accurately predicting the extent of silicon transfer level since the loss of silicon during the droplet zone and the improvement in oxygen content in the molten droplet are not considered, resulting in an overestimation of the ΔSi level. Finally, the limitations of the traditional elemental transfer quantification method and corresponding corrective suggestions are proposed.

With the advancement of the manufacturing industry, performing submerged arc welding subject to varying welding heat inputs has become essential. However, traditional thermodynamic models are insufficient for predicting the effect of welding heat input on elemental transfer behavior. This study aims to develop a model via CALPHAD technology to predict the influence of heat input on essential elements such as O, Si, and Mn when typical SiO₂-bearing fluxes are employed. The predicted data demonstrate that the proposed model effectively forecasts changes in elemental transfer behavior induced by varying welding heat inputs. Furthermore, the study discusses the thermodynamic factors affecting elemental transfer behavior under different heat inputs, supported by both measured compositions and thermodynamic data. These insights may provide theoretical and technical support for flux design, welding material matching, and composition prediction under various heat input conditions subject to submerged arc welding processes when SiO₂-bearing fluxes are employed.

This study investigates the influence of Cr₂O₃-bearing fluxes on the transfer behavior of O and Cr during the submerged arc welding process. A series of fluxes with varying Cr₂O₃ content are prepared and applied in submerged arc welding. A cross-zone model is developed to separately evaluate the transfer of O and Cr in both droplet and weld pool zones. The results reveal significant O enrichment in the droplet zone due to the decomposition of Cr₂O₃ under arc heating, followed by deoxidation in the weld pool. Cr transfer is found to be inhibited by the high oxygen potential in the droplets and further affected by evaporation loss. A comparison of predicted ΔCr values shows that the gas–slag–metal equilibrium model overestimates Cr transfer level, while the cross-zone model provides predictions more consistent with experimental results. This study highlights the critical role of Cr₂O₃ in regulating transfer behaviors O and Cr and provides valuable insights for flux design aimed at achieving precise compositional control and improved weld quality in welding applications.