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<p>In conventional steel welding, filler materials are generally supplied in wire form and must be supplied simultaneously with the heat source, which limits flexibility in welding position and direction. To overcome these limitations, this study proposes a novel concept of gel-type welding filler material that enhances accessibility and simplifies the welding process. The gel-type filler was formulated using Fe–Cr–Ni alloy powders, a polyvinyl alcohol (PVA) binder, and distilled water, ensuring both mechanical compatibility and deposition flexibility. Ten different filler compositions (F1–F10) were fabricated and applied to the root-pass welding of thick carbon steel plates using a disk laser heat source. The resulting welds were evaluated for surface appearance, internal defects, microstructure, and micro-Vickers hardness. The results revealed that specific compositions, such as F4 and F5, produced stable welds without cracks and with controlled hardness (~ 374–455 HV), while extreme compositions like F6 and F8 showed significant hardness variation (577 HV and 402 HV, respectively) and crack formation. This represents the first systematic investigation of the relationship between gel-type filler composition and weld integrity. The findings provide key insights for the development of next-generation welding materials capable of addressing spatial and geometric constraints in real-world industrial applications.</p>

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A novel gel-type welding filler material based on Fe–Cr–Ni alloys for root-pass laser welding of carbon steels

  • 期刊论文

  • 发表日期：

    2025年10月1日

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  • Young-Min Kim,
  • Sangwoo Nam,
  • Insung Hwang,
  • Jason Cheon,
  • Byeong-Jin Kim

摘要

In conventional steel welding, filler materials are generally supplied in wire form and must be supplied simultaneously with the heat source, which limits flexibility in welding position and direction. To overcome these limitations, this study proposes a novel concept of gel-type welding filler material that enhances accessibility and simplifies the welding process. The gel-type filler was formulated using Fe–Cr–Ni alloy powders, a polyvinyl alcohol (PVA) binder, and distilled water, ensuring both mechanical compatibility and deposition flexibility. Ten different filler compositions (F1–F10) were fabricated and applied to the root-pass welding of thick carbon steel plates using a disk laser heat source. The resulting welds were evaluated for surface appearance, internal defects, microstructure, and micro-Vickers hardness. The results revealed that specific compositions, such as F4 and F5, produced stable welds without cracks and with controlled hardness (~ 374–455 HV), while extreme compositions like F6 and F8 showed significant hardness variation (577 HV and 402 HV, respectively) and crack formation. This represents the first systematic investigation of the relationship between gel-type filler composition and weld integrity. The findings provide key insights for the development of next-generation welding materials capable of addressing spatial and geometric constraints in real-world industrial applications.