Abstract
The aim of this paper is presenting the results of the investigation of a new Flux Cored Arc Welding (FCAW) process which will increase productivity, improve welding efficiency and provide more cost-effective method of Temper Bead Welding (TBW) repairs compared with the other commonly used TWB technique such as MMAW and GTAW. An automatic welding rig was established to carry out the TBW using flux cored wire under different conditions. An experimental investigation was carried out to find the optimal parameters of the TBW using FCAW. This was done in order to provide the desired mechanical properties and microstructures without Post-Welding Heat Treatment (PWHT). Due to the difficulties encountered in the determination of residual stresses, the depth of penetration of welds into the base material was used as a guide to control residual stresses. In this study, an analytical solution was used to support the use of TBW to repair damaged structures. This solution is based on statistical and experimental data. These data were used to establish the relationships between the technological parameters of TBW and the factors responsible for the quality of the repaired structures. Material was a commercial C-Mn steel.