Submerged Arc Welding:

A discussion of the welding process and

how welding parameters affect the
chemistry of Corrosion Resistant
Overlays (CRO)
1
 Submerged Arc Welding (SAW)
• Part 1
– The SAW welding process
• Part 2
– Effects of welding parameters on weld metal
chemistry of corrosion resistant overlays (CRO)

2
 Process Characteristics
• High deposition rates – compared to other
welding processes
• Faster travel speeds – compared to other
welding processes
• Economical - High deposition rates and high
travel speeds reduce overall costs

3
 SAW Process Advantages
• Simple - mechanized process, easy to train
machine operators
• Clean environment - minimal smoke or fumes
• Operator friendly - no visible arc, no spatter

4
 Process Limitations
• Welding is done in the flat position
– Can your part be positioned to weld in the flat
position?
– Can circumferential welds be rotated?

5
 SAW Process
Heat of the arc melts
the wire, flux and plate
Fused flux shapes and
protects weld metal Flux covers weld
zone in front of wire

Weld metal

6
 Welding Power Supply
• Supplies electrical power to the electrode - The
heat of the arc melts the electrode and base
plate to form the weld bead.
• Electrical current can be:
– AC or DC
– CV (constant voltage) or CC (constant current)

7
 Influence of Polarity
• DCEP - Deep penetration
• DCEN - Shallow penetration
• AC - Penetration is in between DCEP and DCEN

DCEP AC DCEN
8
 Function of the Wire
• Carries the welding current for the welding arc
• Weld filler metal
• Weld metal chemistry
• Weld metal mechanical properties

9
 Function of the Flux
• Molten flux shields the weld pool
• Affects weld metal chemistry
• Affects weld metal mechanical properties
• Affects weld performance/characteristics
• Fluxes have variable burn-off rates

10
 Types of Fluxes
• Neutral
– Multi-pass, unlimited thickness, high toughness
• Active
– High in deoxidizers, high speed, weld over rust,
limited thickness
• Alloyed
– Addition of Cr, Ni …, enhanced mechanical properties
11
 Welding Variables
• Welding current
• Arc voltage
• Travel speed
• Wire size
• Wire extension

12
 Welding Current
• Controls – Penetration and deposition rate
current = penetration
current = burn-off rate
current = deposition rate

13
 Welding Current
0.651” 0.780”

.256”
.336”

500 amps @ 35 V 600 amps @ 35 V

20 ipm
14
 Arc Voltage
• Arc voltage is a measure of arc length
voltage = bead width
voltage = penetration

15
 Welding Voltage
0.657” 0.629”

.256” .273”

500 amps @ 35 V 500 amps @ 30 V

20 ipm

16
 Welding Voltage
0.503”
0.772”

.336”
.427”

600 amps @ 35 V 600 amps @ 28 V

20 ipm

17
 Travel Speed
• Controls - penetration and volume of metal per
unit length
speed = penetration
speed = weld size, width, reinforcement

18
 Travel Speed
0.669” 0.635” 0.547” 0.490”

0.277” 0.236”

20 ipm 25 ipm 30 ipm 35 ipm

All welds made at 500 amps and 35 volts

19
 Wire Size / Burn-off Rates
• Wire Burn-off rates (ipm) vs. Amps

DCEP - 10-15% Less

DCEN - 10-15% More

Electrode Stick-out = 8X wire diameter

20
 Wire Stick-out
• Wire stick-out should be about 8 times the wire
diameter - (1/8” wire = 1” )
• Electrical Stick-Out (ESO) - Tip-to-work distance
Tip

Stick-out

Work
21
 Effects of ESO
• Longer stick-out – At the same wire feed speed,
decreases welding current and penetration
• Longer stick-out – At the same current, increases
deposition due to the higher burn-off rate
– As stick-out increases, the wire feed speed must be
increased to maintain the same welding current.

22
 Effects of ESO on Deposition Rate
• 3/32” ERNiCrMo-3 wire at 250 amps
Effects of Electrode Stick-out (ESO) on
Deposition Rate, lbs./hr.
14
Deposition rate, lbs./hr.

13 13

12 11.9
11
10.7
10

9
0.5 0.75 1 1.25 1.5 1.75 2
ESO, in.

23
 PART II
Effects of welding parameters on
weld metal chemistry of CRO

24
 Everyone is looking for:
• Increased production
• Increased welding speeds
• Increased deposition rates
• Reduced base metal dilution

25
 Deposition rates for CRO
60
Deposition - lbs./hr.

50

40

30

20

10

0
GTAW-HW SAW Wire SAW 30 mm Strip ESW 60 mm Strip
PROCESS
26
 Flux selection
• Good slag peeling on SS and Ni alloy
• Good edge wetting
• Cr compensating (SS)
• Cr or Ni additive (SS & Ni)

27
Flux selection
Slag sticking to weld
bead with flux - A

After slag removal some

small spots remain

Flux – B was self-

peeling but still has tiger
stripes
28
Flux selection

Free peeling slag with flux - C

Smooth surface with

excellent wetting along
edges of weld bead

29
CRO requirements for ERNiCrMo-3
• Two-layer deposit
• Thickness – 1/8”per layer, 1/4” total
• Chemistry – Fe-5 or Fe-10 at 1/8” above
original surface

30
 Dilution
• Dilution – the percentage of base metal in the
weld bead.
Weld Bead
Base Metal
A
B

% Dilution = [B÷(A+B)] (100)

31
 Objectives
• Determine what welding parameters control
weld metal chemistry.
• Achieving Fe-10 or Fe-5 in two layers

32
 Layer Thickness
• First layer needs to be close to 0.125” thick so
second layer fusion line is below 0.125”.
• The chemistry at 1/8” needs to come out of
the second layer and not the first.

33
 Weld cross sections
Second Layer fusion line needs to be
below the 1/8” above original surface.
Too much penetration will cause too 1/8”
much dilution in the second layer
chemistry.

Second layer fusion line is below

1/8”
the 1/8” above original surface.

There are thee small areas visible 1/8”

from the second layer, but it won’t
pass chemistry.

34
 Factors Affecting Chemistry
• Amperage
• Voltage
• Travel speed
• Electrical stick-out (ESO), Tip-To-Work distance
• Step-over distance

35
 Amperage
• Effects of Amperage on chemistry and
deposition rate.
• 3/32” wire, 1” ESO, 32 volts, 20 ipm

Amps / Sample 250 / A 300 / B 350 / C

Deposition, lbs./Hr. 10.7 13.0 15.5
Chemistry, % Fe 41.14 40.84 44.78

• Amperage has little effect on chemistry

36
 Amperage
Effect of Amperage on Weld Dimensions
0.700

0.600
Weld Dimensions, in

0.500

0.400
Bead Height
0.300
Bead Width
0.200 Depth of Fusion
0.100

0.000
200 220 240 260 280 300 320 340 360
Amperage

37
 Voltage
• Effects of Voltage on chemistry
• 3/32” wire, 1” ESO, 250 amps, 20 ipm

Voltage / Sample 28 / D 30 / E 32 / F
Chemistry, % Fe 41.07 40.23 41.55

• Voltage has no significant effect on

chemistry

38
 Voltage
Effect of Voltage on Weld Dimensions
0.600
Weld Dimensions, in

0.500

0.400

0.300 Bead Height

Bead Width
0.200
Depth of Fusion
0.100

0.000
27 28 29 30 31 32 33
Voltage

39
 Travel Speed
• Effects of travel speed on chemistry
• 3/32” wire, 1” ESO, 250 amps, 32 volts

Travel Speed (ipm) 16 / G 20 / H 24 / I

Chemistry, % Fe 40.76 41.55 42.50

• Travel speed has little effect on chemistry

40
 Travel Speed
Effect of Travel Speed on Weld Dimensions
0.600

0.500
Weld Dimensions, in

0.400

0.300 Bead Height

Bead Width
0.200
Depth of Fusion
0.100

0.000
15 17 19 21 23 25
Travel Speed, in/min

41
 Weld Study Constants
• All the welds for this study were made using
3/32” diameter ERNiCrMo-3 wire.
• All the remaining welds were made at 32 volts.
• All the remaining welds were made at 24 ipm
travel speed.

42
 Electrical stick-out (ESO)
• If amperage is held constant:
• Wire feed speed must increase as ESO
increases
• What happens to dilution?
• % Dilution = [B÷(A+B)] (100) A
B
43
 Electrical Stick-out
• Effects of electrical Stick-out on
deposition rate and chemistry
• ¾”, 1¼”, 1¾” ESO at 250 amps

ESO / Sample ¾”/O 1¼ ” / P 1¾ “ / Q ∆

Deposition, 10.7 11.9 13.0 21.5% >
lbs./Hr.
Chemistry, % Fe 40.90 38.08 32.68 20.1% <

• Increased ESO has positive effect on

deposition rate and weld chemistry.

44
 Effects of ESO on Chemistry

Effect of Electrode Extension on Weld Chemistry

44.00

42.00 40.90
Percent Iron, Fe

40.00
38.08
38.00

36.00

34.00 32.68
32.00

30.00
0.60 0.80 1.00 1.20 1.40 1.60 1.80
ESO, in

45
 Step-over, 1” ESO, 250A

• Effects of step-over on chemistry 3.5 mm Step

• 3.5, 6.0, 8.0 mm step-over at 1” ESO and

250 amps
6.0 mm Step
Step-over, mm 3.5 / J 6.0 / K 8.0 / L
Chemistry, % Fe 9.73 28.97 37.85

• Step-over has a very significant effect on 8.0 mm Step

weld chemistry

46
 Step-over, 1¾” ESO, 250A
• 4.0, 5.0, 6.0 mm at 1¾” ESO and 250 amps (105 ipm)

4 mm 5 mm 6 mm
Step-over / Sample 4mm / R 5mm / S 6mm / T
Chemistry, % Fe 7.65 12.48 16.65

47
 Step-over, 1” ESO, 300A
• 4.0, 5.0, 6.0, 8.0 mm step-over at 1” ESO and 300 amps (105 ipm)

4 mm 5 mm 6 mm 8 mm

Step-over, mm / Sample 4.0 / Y 5.0 / Y 6.0 / M 8.0 / N

Chemistry, % Fe 9.20 19.71 27.34 35.87

48
 Effects of Step-over
Effect of Step-over on Weld Chemistry
40 37.85

35 35.87
28.97
Percent Iron (Fe)

30 20% line
27.34
25

20 19.71 250A, 1 in ESO

16.65
15 300A, 1 in ESO
9.73 12.48
10 9.20 250A, 1 3/4 in ESO
7.75
5

0
2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0
Step-over (mm)

49
 Two Layers, 1” ESO, 250A/300A
• 1” ESO, 250 amps (86 ipm) 1st layer
• 1” ESO, 300 amps (105 ipm) 2nd layer
• Wire feed changed for amperage
• 4.0 mm/5.0 mm step – good chemistry
• 4.0 mm/6.0 mm step – good chemistry
Parameters / Z 1st Layer 2nd Layer 2nd Layer
Amps 250-260 300-310 300-310
Step Distance, in 4.0 mm 5.0 mm 6.0 mm
6mm 5mm
Chemistry, % Fe (1/8”) 13 3.22 4.20
Chemistry, % Fe (1/4”) 3.24 3.68
50
 Two Layers, 1” ESO, 250A/300A
• 1” ESO, 250 amps (86 ipm) 1st layer
• 1” ESO, 300 amps (105 ipm) 2nd layer
• Wire feed changed for amperage
• 4.0 mm step 1st layer
• 6.0 mm step 2nd layer
Parameters / DD 1st Layer 2nd Layer
Amps 250-260 300-310
Step Distance, in 4.0 mm 6.0 mm
Chemistry, % Fe (1/8”) 13 4.20
Chemistry, % Fe (1/4”) 3.68
51
 Two Layers, 1” ESO, 250A/300A
• 1” ESO, 250 amps (86 ipm) 1st layer
• 1” ESO, 300 amps (105 ipm) 2nd layer
• Wire feed changed for amperage
• 6 mm step 1st, 6 mm step 2nd
• Failed to meet Fe-5 at ¼”
Parameters / CC 1st Layer 2nd Layer
Amps 250-260 300-310
Step Distance, in 6.0 mm 6.0 mm
Chemistry, % Fe (1/8”) 22.66 4.98
Chemistry, % Fe (1/4”) 5.57
52
 Two Layers, 1¾” ESO, 250A/300A
• 1¾” ESO, 250 amps (105 ipm), 1st layer
• 1” ESO, 300 amps (105 ipm), 2nd layer
• Change in ESO to change amperage
• 6 mm step 1st, 6 mm step 2nd
• Good weld
Parameters / X 1st Layer 2nd Layer
Amps 250-260 300-310
Step Distance, in 6 mm 6 mm
Chemistry, % Fe (1/8”) 17.0 4.62
Chemistry, % Fe (1/4”) 4.44
53
 Two Layers, 1¾” ESO, 250A/300A
• 1¾” ESO, 250 amps (105 ipm), 1st layer
• 1” ESO, 300 amps (105 ipm), 2nd layer
• Change in ESO to change amperage
• 6 mm step 1st, 5 mm step 2nd
• Chemistry at 1/8” didn’t meet Fe-5
Parameters / BB 1st Layer 2nd Layer
Amps 250-260 300-310
Step Distance, in 6.0 mm 5.0 mm
Chemistry, % Fe (1/8”) 17 7.59
Chemistry, % Fe (1/4”) 3.94
54
 Two Layers, 1” ESO, 300A/300A
• 1” ESO, 300 amps (105 ipm), 1st layer
• 1” ESO, 300 amps (105 ipm), 2nd layer
• 4.5 mm step 1st layer
• 4.5 mm step 2nd layer
• Reinforcement too thick – 0.293”
Parameters / AA 1st Layer 2nd Layer
Amps 300-310 310-320
Step Distance, in 4.5 mm 4.5 mm
Chemistry, % Fe (1/8”) 10.5 3.03
Chemistry, % Fe (1/4”) 3.38
55
 Two Layers, 1” ESO, 300A/300A
• 1” ESO, 300 amps (105 ipm), 1st layer
• 1” ESO, 300 amps (105 ipm), 2nd layer
• 5 mm step 1st layer
• 5 mm step 2nd layer
• Good weld
Parameters / EE 1st Layer 2nd Layer
Amps 300-310 300-310
Step Distance, in 5.0 mm 5.0 mm
Chemistry, % Fe (1/8”) 14.26 3.94
Chemistry, % Fe (1/4”) 4.49
56
 Key Factors
• Keep first layer ≤ 1/8” thick
• Keep first layer chemistry less than 18%
• Second layer fusion line must be below 1/8”, but not too much
• Second layer dilution needs to be less than 20%
• Keep overall thickness close to ¼”; don’t over-weld
• Step-over distance is critical, need for precise control

57
 Conclusion
• Traditional amps, volts and travel speed have minimal effect
on weld metal chemistry.
• ESO increases deposition rate at a given current. This reduces
iron content.
• Step-over has the greatest influence on weld metal chemistry.
• Check first and second layer chemistry and thickness.
• Check weld cross section if needed.
• Accurate step-over control is critical

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 Q&A

dave@arcspecialties.com

59