What Is Ceramics? Where Is It Used? How Is It Used?

What Is Ceramic? Where Is It Used? How Is It Used?

Since it was first introduced in the shipbuilding industry, ceramic has quickly established itself in the welding sector. It is widely used in general manufacturing, pressure vessels, bridges, and heavy machinery production.

The most significant advantage of ceramic backing plates is that they facilitate root welding on parts that are critical to the manufacturing process. This eliminates the need for additional operations such as re-cleaning and repositioning parts, thereby reducing labor time and improving overall cost efficiency.

Luchs ceramic welding backing plates enable operation at higher amperages, allowing for high weld metal deposition rates. The solidified weld metal easily conforms to the shape of the ceramic backing plate, eliminating the need for cleaning and re-welding on the other side of the part.

Using ceramic welding backing plates is quite simple, and it doesn’t take long for welders to start using them.

Before using ceramic backing plates, it is important to clean the surface where the backing plate will be placed of dust and grease. Leave a 4–5 mm gap between the parts, remove the paper from the adhesive foil, and firmly attach it to the back of the welding nozzle. Make sure the welding nozzle is aligned with the ceramic groove surface.

If you are using 1.2 mm diameter wire, perform the root pass at 160–180 A and 23–25 V, allowing the welding wire to move freely in front of the torch. During root welding, make sure the edges of the parts are slightly melted. Be careful not to swing the torch excessively while welding in the groove position, as this can cause the weld to bulge.

When welding in the PF position (bottom-up), hold the torch at an angle of approximately 10° and weld without oscillation at a current of 180–190 A and a voltage of 23–27 V, at a speed of 180–200 mm/min. For filler pass welds, tilt the torch toward the axis and, while welding from bottom to top, use a oscillating technique to ensure the edges of the weld joints melt.

Ceramic welding pads can retain their properties for a long time without deterioration under proper storage conditions. However, it is important not to use ceramic backing plates that have been in storage for a long time for root welds in critical applications. Ceramics that have been stored for a long time can retain moisture on their surfaces, and this moisture can transfer to the weld pool, negatively affecting weld quality. Due to the hydrogen they contain, this situation can lead to a decrease in mechanical strength and hydrogen embrittlement.

Leaving excessive gaps in ceramic welding backing plates or welding with very high amperage and voltage values can cause hot tearing in the material. Therefore, you should ensure a controlled heat input and weld while leaving gaps only to the extent permitted by the ceramic’s geometry.