A Novel Ceramic Backing Strip from Metakaolin-Based Geopolymer with Gas Flow Holes for Welding Application

Abstract

This research is firstly presented the thermal resistance of a ceramic backing made from metakaolin-based geopolymer for stainless steel welding. The general problems such as lack of fusion, hydrogen inclusion, porosity and corrosions of stainless steel welded specimens were found because, largely, stainless steel presents an affinity to gases as oxidation. Therefore, during welding, if these gases do not escape from the weld pool before solidification of weld metal, it results in porosities or hydrogen inclusions. In this case, it can be solved by properly using inert gas backing. The welder usually uses the steel backing plate with a gas release hole to support weld root and gas transmission for completed weld penetration and superior weld quality. Since the geopolymer shows a good property of thermal resistance, researchers are interested in using the ceramic backing made from geopolymer instead of the commercial ceramic backing. The ceramic backings from the geopolymer were designed merely in 3 types as follows: Narrow curved groove without gas release hole, narrow curved groove with gas release holes and wide curved groove with gas release holes. Consequently, two pieces of stainless steel were welded by gas tungsten arc welding and then the weld quality such as defects, porosity and root penetration of welded specimens was inspected. Moreover, the surface failure of ceramic backing after the welding process was also considered. The results revealed that ceramic backing from a geopolymer with wide curved groove and gas release holes gave completed penetration at the root when inspecting with non-destructive testing such as visual test, penetration test, and radiography test. It was concluded that the geopolymer could be used as ceramic backing in stainless steel welding by gas tungsten arc welding. Moreover, it could be used as backing for aluminum and steel welding as well.

Possibilities of Using Geopolymers in Welding Processes and Protection against High Temperatures

“…The literature also reports the possibility of using geopolymers as ceramic primers for welding stainless steels. Paper [23] presents the thermal resistance of a ceramic primer made of a metakaolin-based geopolymer for welding stainless steel. Geopolymer ceramic primers were designed in three types.…”