Determining the Degree of Admixing Rate of the Base Material and the Melting Efficiency in Single-Bead Surface Welds Using Different Methods, Including New Approaches

The precise determination of the admixing rate of the base material for certain welding parameters is very important because of the possible negative consequences. As such, it is the basis for corrections in welding technology. In the article, experimental and theoretical determinations of the admixing rate in single-bead surface welds that were arc welded onto S355 steel with different alloyed-steel-coated electrodes are discussed. The admixing rate was experimentally estimated from the ratio of the surface areas of metallographic cross-sections, from the ratios of the height and from chemical analyses of different regions of the surface weld, while it was theoretically estimated from the characteristics of the welding process and material constants. One of the key characteristics of the welding process is the melting efficiency, which can be estimated by means of different equations and from knowledge of the heat balance of the welding process. Both the average melting efficiency of the surface welding on the medium-thick S355 steel plate and the average admixing rate of the S355 steel into the surface welds have the same value, i.e., approximately 30%. New equations for estimating the melting efficiency of the arc welding with a coated electrode were developed on the basis of the results.