SUBMERGED ARC WELDING

Definition :

SAW Produces
coalescence of metals
by heating with an arc
between a bare metal
electrode & the work.
The arc & molten metal
arc are submerged in a
blanket of granular
fusible flux on the
work.
SUBMERGED ARC WELDING
Selection of SAW depends on :

 Weld metal properties (Both Chemical &

Mechanical)
 Thickness of base metal
 Joint accessibility
 Frequency / volume of welding
 Position of Welding
 SUBMERGED ARC WELDING
General Methods :

 Automatic :
Eqpt that performs the welding without requiring welding operator to
continually monitor & to adjust controls.Expensive self-regulating system is
required to achieve high production rates.
 Machine :
that performs the welding with welding operator to position the work , start
stop welding , adjust controls & to set the welding speed for each run.
 Semi-automatic :
Eqpt. that performs with a hand-held welding gun, which delivers both
flux & the electrode .Wire feeder is used to drive the electrode & flux is
supplied thro’ gravity hopper.It is best suited for small diameter electrode
& moderate travel speed.
SUBMERGED ARC WELDING
Essential Components of SAW :

 Power Source
1) DC supply from a transformer-rectifier / motor /
Engine generator(400 A to 1500 A )
2) AC supply from a transformer
(800 A to 1500 A)
 Weld Head & Torches ( Electrode delivery system)
 Accessory Equipments
1) Flux Recovery Unit
2) Positioner & Fixtures
SUBMERGED ARC WELDING
Welding Head & Torch :

 Wire feed motor

 Feed roll assembly
 Torch Assembly
 Contact Tip
 Flux Nozzle
 Accessories for mounting & positioning the head
SUBMERGED ARC WELDING
Accessory Equipments :
Flux Recovery Units :
- Used to maximize the flux utilization & minimize manual clean-up.
Other Benefits are
1) remove the unused flux & fused slag behind the weld head.
2) recirculate flux back to the hopper for reuse.
3) screen out fused slag & other oversized particles.

Positioners & Fixtures :

- Because SAW is limited to Flat & Horizontal position welding ,
positioners & fixtures are widely used.
Eg.Turning rolls ,tilting-rotating positioners,custom
fixturing includes positioners to aid in setting up,positioning &
holding the workpiece.
SUBMER GED ARC WELDING
Materials :

Base material :
1) Carbon Steel upto 0.29% Carbon
2) Low Alloy steel with max. yield strength of 690 MPa
3) Cr-Mo Steels ( ½ to 9 % Cr ,½ to 1 % Mo)
4) Stainless Steel
5) Nickel-base alloys
Electrodes :
1) Bare Electrode 2) Composite metal cored electrodes
 Packed as coils or drums ranging in weight from 11 kg to 454 kg
 Steel electrodes are copper coated to provide good shelf life, contact tube w
& increase electrical conductivity
 Electrode size ranges from 1.6mm to 6.4 mm in dia
 SUBMERGED ARC WELDING
Materials (Contd..)
Fluxes :
Its major role are
1) Protects the molten pool & arc against atmospheric Oxygen & N2
2) Controls the weld bead profile
3) Modifies the chemical properties of the weld metal
Properties are
1) Shall be granular & capable of free flowing
2) Solid state shall be non conductive but when molten it comes highly
conductive medium
3) Particle size shall be controlled
4) Remain molten till the weld metal solidifies.
5) Viscosity - Prevent atm. Contamination & shall not run away from the
molten metal.
6) Basicity Index
 SUBMERGED ARC WELDING
Materials (Contd..)
Types of Fluxes :
 Fused Fluxes
 Agglomerated / Bonded Fluxes
 Mechanically mixed Fluxes

CaO+CaF2+MgO+K2O+Na2O+1/2(MnO+FeO)
Basicity Index=
SiO2+1/2(Al2O3+TiO2+ZrO2)

BI < 1 - ACIDIC
BI 1-1.5 - NEUTRAL
BI 1.5-2.5 SEMI BASIC
BI > 2.5 BASIC

AS BI , Si & Mn ; ALSO Oxygen

 SUBMERGED ARC WELDING
Materials
Active Fluxes Neutral fluxes
Contain deoxidizers such as W M chemistry is close to
Si, Mn Electrode chemistry & is not
W M chemistry is sensitive to sensitive to changes in arc
changes in arc voltage voltage
Can be used on heavily oxidized
surfaces

Classification of Flux:
FXXX-EXXX ( Eg.F48P4-EH14)
Electrode Classification - EH14
Electrode
Max.Impact test tempt (°C)
As weld / post weld
Tensile Str. In MPa
Flux
 SUBMERGED ARC WELDING
Process parameters :

Welding Amperage :
It controls
1) Rate at which electrode melts
2) Deposition rate
3) Depth of penetration&
4) Amount BM melted

High Current Low Current

deposition rate, depth of fusion Inadequate depth of fusion,
 weld shrinkage, distortion, Unstable arc
width of HAZ, in mechanical
properties like Hardness,
Tensile strength , Impact
strength.
SUBMERGED ARC WELDING
Process parameters (Contd..):
Welding Voltage :
It controls
1) Alters the arc length
2) Determines the shape of the weld bead cross-section & its external
appearance.
3) Little effect on deposition rate

With increasing V With decreasing V

Flatter & Wider bead Stiffer arc improving penetration in
Bridges excessive root opening deep grooves & resists arc blow
Slag removal is difficult with too high
V
Increases flux consumption & pick-up High narrow bead & causes difficult slag
of ferroalloys removal along the edges of the weld.
Undercut along the edges of fillet weld.
 SUBMERGED ARC WELDING
Process parameters (Contd..):

Travel Speed :
It controls
1) With the combination of I, V ,it determines the heat input per unit length
of the weld
With increasing Travel Speed With decreasing Travel Speed
Heat Input per unit length of the weld Heat Input per unit length of the weld & it
& less FM is consumed per unit length impairs the Impact properties & hardness
of the weld
Promotes undercut,porosity,arc Convex weld bead leads to crack,
blow,uneven bead shape Increases the width of the HAZ
Weld bead is smaller
Depth of penetration, Deposition rate
Depth of penetration, Allows time for gases to from the WM
thus reduces the porosity
SUBMERGED ARC WELDING
Process parameters (Contd..):
Electrode Size:
Its affects ( @ fixed Current)
1) Depth of penetration
2) Weld bead shape

Small Diameters :
- used in semi-automatic welding,multiple arcing system
- not suitable for bridging large root openings

Large Diameters :
- produces higher deposition rates @ higher current
- suitable for bridging large root openings
SUBMERGED ARC WELDING
Process parameters (Contd..):
Electrode Extension (Electrode Stick out ):
It refers the length of the electrode between the end of the contact
tube & the arc. Ideal length = 8 X Dia. of the electrode.

Increasing Stick out Length :

- At higher current density , greater amt. of heating takes place by I2R
hence the higher melting rate with higher deposition rate (25% to 50%
- Used to weld thin material without any melt thro
- Increase the flux consumption by 15 % in DCRP.
SUBMERGED ARC WELDING
Process parameters (Contd..):

Width & Depth of Flux:

It controls
1) Appearance & soundness of the finished weld
2) Welding Action

Flux layer too deep Flux layer is too shallow

Arc is too confined resulting in a Arc is not entirely
rough rope-like weld submerged in flux

Degassing becomes difficult; Flashing & spattering occurs

Weld surface becomes
irregularly distorted
 SUBMERGED ARC WELDING
Advantages & Applications:

Advantage:
 Absence of smoke & arc flash hence less protective clothing is
required.
 High Weld metal Quality
 Higher deposition rate & welding speed
 Smooth & uniform weld finish with no spatter
 Less welding operator skill is required
 High arc time can be achieved thro’ automation.
Applications:
 Extensively used in the heavy steel fabrication of Pressure
vessels, storage tanks,line pipes,ships, railway wagons&
coaches,heavy structurals, surfacing & buildup work.
SUBMERGED ARC WELDING
Weld Discontinuities:

Major Discontinuities are

 Cracks
 Porosity
 Slag
 Incomplete fusion or Lack of Fusion
Cracks:
It can be caused by
 Diffusible Hydrogen in the weld metal
 Joint geometry
 Welding variables like Heat input
 Stress at the point where the weld metal is solidifying.
 Smooth & uniform weld finish with no spatter
SUBMERGED ARC WELDING
Weld Discontinuities(Contd..):
Porosity:
 Inadequate flux coverage
 Contaminants in the flux & weld joint
 Excessive travel speed
 Slag residue from tack welds made with covered electrodes

Lack of Fusion:
 Joint Geometry
 Inadequate Heat Input

Slag:
 Contaminants of flux
 Usage of cold flux.
 Joint geometry
 Improper removal of slag after each pass
 Viscosity of the flux
SUBMERGED ARC WELDING
Process Variations:

 Tandem SAW
 Twin wire SAW
 Single wire SAW with auxiliary hot wire feeding
 Single wire SAW with metal powder addition
 SA Strip Clading
SUBMERGED ARC WELDING
Tandem Arc SAW :
 Uses a DCEP lead electrode and an AC trail electrode
(separated by a distance of 19-20 mm)
 Can be used with two AC power sources (Scott
connection) or one DC& One AC
SUBMERGED ARC (SASC) /
ELECTRO SLAG STRIP
CLADDING (ESSC)
APPLICATION
 FREQUENTLY USED FOR OVERLAYING
INNER SURFACES OF HEAVY WALL
PRESSURE VESSELS SUCH AS
EQUIPMENTS FOR OIL & REFINERY
PLANTS, FERTILIZER PLANTS, NUCLEAR
PLANTS AND MANY MORE-------
SASC : PROCESS PRINCIPLE

 PROCESS IN ALL RESPECTS COMPARABLE WITH

SAW
 COALESCENCE OBTAINED THROUGH A DC ARC
STRUCK BETWEEN THE STRIP ELECTRODE AND
THE BASE METAL
 ARC AND THE WELD POOL ARE SHIELDED BY A
CONTINUOUS SUPPLY OF FLUX
FACTORS DECIDING WELD
METAL COMPOSITION
 COMPOSITION OF THE WELD METAL IS
DETERMINED BY:
--> FILLER METAL USED
--> LEVEL OF DILUTION FROM THE

BASE MATERIAL
--> METAL LOSS DURING DEPOSITION
--> ALLOYING FROM THE FLUX
 PROCESS VARIABLES &
EFFECTS
 MACHINE VARIABLES
--> WELDING CURRENT
--> WELDING VOLTAGE
--> TRAVEL SPEED

 FLUX
 STRIP SIZE & COMPOSITION
 BASE METAL
EFFECT OF MACHINE
VARIABLES
 Cr CONTENT IS AFFECTED BY
VOLTAGE.
 Si AND Mn CONTENTS ARE LESS
INFLUENCED.
 OTHER ALLOYING ELEMENTS ARE
PRACTICALLY NOT INFLUENCED AT
ALL BY THE MACHINE SETTINGS.
ROLE OF WELDING FLUX
 FLUXES ARE COMPOSED IN SUCH A
WAY AS TO PERMIT THE VISCOSITY
AND SURFACE TENSION OF THE
SLAG TO SUSTAIN THE MOLTEN
POOL &
 FORM EDGES OF THE WELD BEAD.
 ROLE OF WELDING FLUX
 FLUX HEIGHT(OR BURDEN) SHALL BE
0-5MM MORE THAN THE STICK OUT.
 HIGHER FLUX BURDEN RESULTS IN :
--> INCREASED FLUX CONSUMPTION
--> REDUCED DEGASSING.
 SHALLOW FLUX BURDEN TENDS TO
INCREASE ARCING & LIQUID METAL
SPATTER.
ESSC : PROCESS PRINCIPLE
 ESSC IS DIFFERENT FROM SASC IN
NATURE OF FLUX, AND THE WAY IT
IS FED.
 HEAT REQUIRED FOR PRODUCING
COALESCENCE IS DERIVED FROM
THE RESISTIVE HEAT OF THE SLAG.
HOW DO ESSC DIFFERS ???
 FLUX MUST BE FREE OF A GAS
GENERATING AGENT (CaCO3).
 A SPECIFIED DEPTH OF SLAG POOL
EXISTS.
 MAGNETIC STEERING
CONTROL
 UNDERCUT AND WELD BEAD DISORDERS
ARE THE PROBLEMS ENCOUNTERED WITH
ESSC.
 UNDERCUT IS CAUSED DUE TO MAGNETIC
FIELD RESULTING FROM WELDING
CURRENT.
 WELD BEADS CAN BE AFFECTED BY
UNBALANCED MAGNETIC FIELD ARISING
FROM GROUND CABLE (PLACED NEAR TO
THE MATERIAL TO BE WELDED)
INFLUENCE OF WELDING
CONDITIONS
 WELDING CURRENT
 WELDING VOLTAGE
 WELDING SPEED
 INCLINATION OF BASE MATERIAL
 FLUX BURDEN
EFFECT OF WELDING CURRENT
DILUTION DECREASES AS CURRENT
INCREASES
TOO HIGH A CURRENT RESULT IN INCREASED
ARCING AND SLAG SPATTER

EFFECT OF WELDING VOLTAGE

ESSC WORKS IN A LOWER RANGE OF
VOLTAGE (24 TO 26V)
IF VOLTAGE IS HIGH, ARCING OCCURS,
MAKING THE PROCESS UNSTABLE
EFFECT OF WELDING SPEED
BEAD WIDTH AND HEIGHT DECREASES AS
SPEED INCREASES
DILUTION INCREASES AS SPEED
INCREASES

EFFECT OF BASE MATERIAL SLOPE

IT IS RECOMMENDED THAT BASE
MATERIAL SHOULD BE PLACED FLAT FOR
WELDING
EFFECT OF FLUX BURDEN
 FLUX HEIGHT(OR BURDEN) SHALL BE 0-
5MM MORE THAN THE STICK OUT.
 HIGHER FLUX BURDEN RESULTS IN : -->
INCREASED FLUX CONSUMPTION -->
REDUCED DEGASSING.
 SHALLOW FLUX BURDEN TENDS TO
INCREASE ARCING & LIQUID METAL
SPATTER.
 COMPARASION OF SASC &
ESSC SASC ESSC
STRIP SIZE 60 x 0.5 60 x 0.5
PARAMETERS
CURRENT 750 1250
VOLTAGE 26-30 23-25
SPEED 130-150 150-180
HEAT GENERATION arc electrical res.
DILUTION % 16-20 8-10
DEPOSITION RATE (Kg/arc-hr) 14 22
FLUX CONSUMP.(Kg/KgStrip) 1.1 0.8