Theoretical and experimental assessment of chloride effects in the A-TlG welding of magnesium

Active fluxes that are deposited on the TIG torch path before alloy melting can significantly increase weld penetrations. Several mechanisms (arc constriction, surface-tension-driven flow) for the active-TIG or A-TIG welding process have been postulated. The A-TIG welding of magnesium is discussed here using a simple model for the surface tension over the weld pool, real-time monitoring data, and measured characteristics from the fusion zone region. The chlorides selected for this investigation incorporated simple-metal elements from different group numbers (LiIACl, CaIIACl2, CdIIBC12, PbIVBCl2 and CeCl3) so that correlations between their chemistry and their effects during A-TIG welding could be established. Video recordings showed that chlorides intensified the visible light emission from the arc and affected its profile. Measurements during arc welding at a constant current demonstrated that all chlorides increased the arc voltage (thus the heat input) and the arc temperature. A-TIG weld cross sections revealed that chlorides increased fusion zone dimensions, as could be expected from greater heat inputs. While calculations suggested that surface tension might have altered weld pool circulation, specially designed experiments with low-energy-density laser beams were inconclusive. Among all tested chlorides, cadmium chloride was the most effective during A-TIG welding due to the high first ionization potential of cadmium, which correlated to several observations such as: low chloride melting, boiling, and dissociation temperatures, high welding voltage, augmented arc temperature, increased fusion zone penetration, and greater depth-to-width ratio.