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Hybrid Optimization of Hardfacing Conditions and the Content of Exothermic Additions in the Core Filler During the Flux-Cored Arc Welding Process

B. Trembach,O. Dmitriiev,Kostiantyn Kulahin,Oleksii Balenko,Volodymyr Maliuha,L. Neduzha

Published 2026 in Engineer

ABSTRACT

This study introduces a hybrid optimization method to enhance the melting characteristics and weld bead morphology of flux-cored wire hardfacing with exothermic addition into the core filler. The Taguchi Design of Experiments (L9 orthogonal array) was used to analyze the effects of key conditions on multiple melting characteristics. The hybrid Taguchi-GRA-PCA effectively identified the best parameter combination, resulting in a significant improvement in overall melting performance. The impact of welding modes on weld bead parameters and melting characteristics was examined. It was determined that the optimal amount of the exothermic addition CuO-Al introduced into the flux-cored wire filler should be a medium level (EA = 28 wt.%). Results showed that wire feed speed WFS and EA had the greatest effect on MOR and DR, while EA and CTWD mainly influenced SF and De. It has been determined that the content of the exothermic additive has a significant impact on the melting process of filler materials, affecting the melting characteristics and weld bead morphology. It has been found that the melting characteristics of deposition rate and spattering factor can be used to optimize welding modes and characterize most output parameters of the welding/surfacing process.

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