This study presents a novel ilmenite-based shielded metal arc welding (SMAW) electrode developed to promote sustainable and resource-efficient manufacturing. To provide a cost-effective alternative to conventional rutile fluxes, natural rutile was substituted with size-reduced ilmenite and potassium titanate, incorporated as additives to enhance arc stability, reduce fume emissions, and improve weld quality. Electrodes with 20–100% rutile replacement were fabricated under optimized coating and processing conditions to ensure uniformity and reproducibility. Comprehensive evaluations included arc stability, fume formation rate (FFR), spatter characteristics, elemental transfer efficiency, weld metal chemistry, and mechanical performance. The optimized formulation achieved a 77.51% reduction in FFR compared with the conventional electrode, attributed to improved arc stability and reduced vaporization of metallic species. XRF and delta-quantity analyses confirmed enhanced transfer of Fe, Mn, Si, and Ti into the weld metal. Microstructural examination revealed refined ferrite grains and increased acicular ferrite, contributing to improvements of 6.68% in tensile strength, 14.66% in bend strength, 13.22% in impact toughness, and 13.27% in microhardness. Radiographic testing confirmed defect-free welds, and flux cost analysis indicated material savings of up to 25%. These findings demonstrate the electrode’s potential as a scalable, high-performance, and economically competitive solution for sustainable welding applications.
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