The Effect of Preheating and Current on the Development of Mild Steel Clad Layers via Stick Welding

Abstract

In surface melting, the preheating temperature is generally caused by the heat conduction through the substrate ahead of the molten pool, and their presence helps to increase the material dissolution. In this work, a comparative study was conducted to study the melt features of two samples produced at 100 A and 70 A using the stick welding process. The effect of the preheating at 100 A and 70 A  on the defects, melt dimensions, surface roughness, deposition rates, and losses between samples were examined. It was found that all samples were free from crack, undercutting, or lack of fusion suggesting selected processing conditions and materials were successfully employed to hinder the problems.  The clad at 100 A was associated with higher preheating temperatures and explained the reason for easing melt dissolution for finer rippling marks and surface roughness. The work demonstrated enormous spatter which was related to the burning of the electrode coating and metal evaporation that had brought the deposition rate to 100 A similar at 0.15 g/sec to the low spatter 70 A track. Low heat input can be the foundation for building high clad thickness  and more dilution through high energy input is preferable  for welding between two metals