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Economic welding of thick steel plates is an emerging challenge for various engineering applications. However, tungsten inert gas (TIG) arc welding, as an economic and widely used method, is not regarded as a suitable tool to weld thick steel plates due to the shallow penetration in a single-pass operation. In this technical progress, the joining of austenitic high manganese steel of 8 mm thickness was successfully performed using nanowire flux activated TIG welding with a full penetration and a narrow bead geometry. Fe2O3 nanowire was used as flux and compared with microscale Fe2O3 flux. Experimental results showed that with nanowire fluxes, the welding yielded the maximum of more than 8 mm thick penetration (full penetration and melt over the plate) with proper operating parameters in a single pass. In sharp contrast, the penetration is only less than 4 mm for a single pass welding without Fe2O3 flux with the similar parameters. Arc voltage—time variation during welding process was analyzed and the angular distortion was measured after welding to understand the activating effect of optimized flux mixture. Compared to welding joint without flux and with microscale Fe2O3 flux, nanoscale Fe2O3 flux has a larger arc voltage and higher energy efficiency, higher joint strength and less angular distortion. The developed joint with nanowire flux qualified the tensile test with tensile strength of 700.7 MPa (82.38% of base material strength) and 34.1% elongation. This work may pave a way for nanotechnology-enabling welding innovation for engineering application.

Fe2O3 Nanowire Flux Enabling Tungsten Inert Gas Welding of High-Manganese Steel Thick Plates with Improved Mechanical Properties