Ferrosilicon is an essential alloy of Iron and Silicon manufactured usually in a Submerged Arc Furnace by smelting Quartz with Coal. The process is very energy intensive, and the high cost of production is justified by its irreplaceable use in Steel manufacturing globally. A total of 5,915,400 tons of ferrosilicon was produced globally in 2022, of which, according to the survey, 75.3% was used in the steelmaking industry and 13.7% in foundry.
Today, we going to talk about another use of Ferrosilicon powder, particularly Atomized ferrosilicon powder in manufacturing of Welding electrodes and Flux cored wires.
Atomized ferrosilicon is commonly used in welding electrodes for various purposes. Here are some roles it plays:
-
Deoxidizer: Ferrosilicon is often added to welding electrodes as a deoxidizing agent. During the welding process, especially in processes like shielded metal arc welding (SMAW), oxygen from the atmosphere can react with the molten weld pool, leading to the formation of undesirable oxides in the weld metal. Ferrosilicon helps to remove these oxides by reacting with oxygen to form slag, which can be easily removed from the weld surface.
-
Alloying agent: Ferrosilicon contains both iron and silicon, which are important alloying elements in welding electrodes. Silicon increases the fluidity of the weld metal, making it easier to control the welding process and ensuring better weld quality. Iron contributes to the strength and toughness of the weld metal.
-
Controlled cooling: Atomized ferrosilicon can be used to control the cooling rate of the weld metal. By adjusting the composition of the welding electrode, particularly the amount of ferrosilicon added, welders can influence the cooling rate of the weld metal, which in turn affects the microstructure and mechanical properties of the weld joint.
-
Fluxing agent: In some cases, ferrosilicon may also act as a fluxing agent in welding electrodes. Fluxes are materials added to the welding process to protect the molten weld pool from atmospheric contamination and to facilitate the removal of impurities from the weld metal. Ferrosilicon can participate in fluxing reactions, helping to improve the quality and cleanliness of the weld.
-
Control of arc stability: The presence of ferrosilicon in the welding electrode can affect the stability of the welding arc. The composition and properties of the electrode, including the ferrosilicon content, can be optimized to ensure a stable arc throughout the welding process, leading to better weld penetration and deposition rates.
Overall, atomized ferrosilicon plays several crucial roles in welding electrodes, including deoxidization, alloying, controlled cooling, fluxing, and arc stability, all of which contribute to the quality and performance of the welded joints.
We at Aim Alloys LLP are the only manufacturer of Atomized Ferrosilicon based in India with an annual production capacity of over 2000 MT. We are able to offer you quality matching international standards for Atomized ferrosilicon powder. Feel free to share your enquiries on info@aimalloys.in