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Manufacturing and mass production have been the main factors propelling the drive towards innovation and technological advancement. The principal substance in materials science that has driven this technological drive is metal, and of all the metals, Aluminum is of inestemable value. Welding is the main bane of manufacturing. It is the process used to join two or more pieces of metals permanently together. Aluminum welding, which is the main target of this research, is particularly dependent on the utilization of a suitable welding flux to achieve excellent results. Aluminum is ubiquitous in application and is of great relevance in nearly all fields of technological development and research, invariably, the same applies to its welding flux. Fluxes are invaluable because they facilitate the removal of the Tenacious Aluminum Hydrated Oxide layer (AlOH) which is always found on Aluminum surfaces which have been exposed to atmospheric oxygen. If this Aluminum oxide layer is not removed before or during welding, its chemical constituents, unless reduced to trace amounts, will act as impurities that would significantly compromise the quality of the weld. It is therefore important to understand the characteristics, the chemical composition, morphological personality, and the weld adaptability of Aluminum and its alloys; in general, a multiphysical approach. All geared towards the realization of an optimal flux composition for Aluminum fluxes. In this chapter, the physics of Aluminum flux composition development process is studied applying several optimization models. To improve on the quality of the welding processes, new ways of developing and optimizing welding fluxes are being investigated with focus on statistical quality control. However, Jackson (1973) was of the opinion that the complex welding technology prevalent in the 1970’s demands an understanding of the formulation, manufacture, performance and use of welding fluxes. This statement still holds true even today. He emphasized that the technology leading to proper flux formulation has been little understood. Natalie et al, (1986) said that new engineering requirements demand innovative approaches to the formulation and manufacture of a welding flux. They also observed that the need for higher quality finished metal products, for applications requiring both higher strength and toughness, demands better control of the weld metal composition in the aftermath of any welding using fluxes. In recent years, mechanical properties such as strength or ductility have been in higher demand in engineering projects, as components are designed to carry even heavier loads.

A Multiphysics Analysis of Aluminum Welding Flux Composition Optimization Methods