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13.0 SUBMERGED ARC WELDING
13.1 THE PROCESS
Abbreviated as SAW, this is a welding process where an arc is struck between
a continuous bare wire and the parent plate. The arc, electrode end and the molten
pool are submerged in an agglomerated or fused powdered flux, which turns, into a
slag in its lower layers when subjected to the heat of the arc, thus protecting the weld
from contamination. The wire electrode is fed continuously by a feed unit of motor-
driven rollers, which usually are voltage-controlled to ensure an arc of constant length.
The flux is fed from a hopper fixed to the welding head, and a tube from the hopper
spreads the flux in a continuous elongated mound in front of the arc along the line of
the intended weld and of sufficient depth to submerge the arc completely so that there
is no spatter, the weld is shielded from the atmosphere, and there are no ultra-violet or
infra-red radiation effects (see figure below. !nmelted flux is reclaimed for use. The
use of powdered flux restricts the process to the flat and hori"ontal-vertical welding
positions.
#ubmerged arc welding is noted for its ability to employ high weld currents
owing to the properties and functions of the flux. #uch currents give deep penetration
and high dilution where twice as much parent metal as wire electrode is melted.
$enerally a DC electrode positive polarity is employed up to about %&&& amps
because it produces a deep penetration. 'n some applications (i.e. cladding
operations DC electrode negative is used due to the shallower penetration and
reduced dilution. At higher currents or in case of multiple electrode systems, AC is
often preferred to avoid the problem of arc blow (when used with multiple electrode
systems, DC electrode positive is used for the lead arc and AC is used for the trail
arc.
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1ifficulties sometimes arise in ensuring conformity of the weld with a
predetermined line owing to the obscuring effect of the flux. (here possible, a guide
wheel to run in the joint preparation is positioned in front of the welding head and flux
hoppers.
#ubmerged arc welding is widely used in the fabrication of ships, pressure
vessels, line pipe, railway carriages and anywhere where long welds are re2uired. )t
can be used to weld thicknesses from %,3 mm upwards.
Materials ji!e"
welding of carbon steels
welding low alloy steels (e.g. fine grained and creep resisting
welding stainless steels
welding 4ickel alloys
cladding to base metals to improve wear and corrosion resistance
13.# $LU%ES
The fluxes may be defined as granular mineral compounds mixed to various
formulations.
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Type of fluxes
Agglomerated 5used
4eutral Acid 6asic 7ighly basic
(elding characteristics (more stable arc, improved weld
appearance, easier slag removal, higher welding speeds
(eld metal mechanical properties (8#, !T# and .94
amount of :n and #i
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The fused fluxes are produced when the constituents are dry mixed and melted
in an electric furnace and thereafter granulated by pouring the molten mixture into
water or onto an ice block. #ubse2uently, these particles are crushed and screened to
yield a uniform glass-like product.
Advantages of fused fluxes;
good chemical homogeneity
less hygroscopic thus handling and storage are easier
allow fines (fine powders to be removed without changes in composition
they can easily be recycled through the system without significant change in
particle si"e or composition
1isadvantages of fused fluxes;
limitations in composition as some components such as basic carbonates would
be unable to withstand the melting process
difficult to add deoxidises and ferro-alloys (due to segregation or extremely high
loss
)n case of agglomerated fluxes constituents may be bonded by mixing the dry
constituents with <otassium or #odium #ilicate. This wet mixture is then pelletised,
dried, crushed and screened to si"e.
Advantages of agglomerated fluxes;
deoxidises and alloying elements can easily be added to the flux to adjust the weld
metal composition
allow a thicker flux layer when welding
can be identified by colour coding
1isadvantages of agglomerated fluxes;
are generally more hygroscopic (re2uires baking
gas may be evolved from the slag as it is melted, leading to porosity
there may be changes in weld metal chemical composition from the segregation of
fine particles produced by the mechanical handling of the granulated flux
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13.3 PROCESS &ARIABLES
There are several variables which when changed can have an effect on the
weld appearance and mechanical properties;
%. (elding current
/. Type of flux and particle distribution
*. Arc voltage
=. Travel speed
3. >lectrode si"e
-. >lectrode extension
?. Type of electrode
@. (idth and depth of the layer of flux
A. >lectrode angle, (0eading, Trailing
%&. <olarity
%%. #ingle, double or multi wire system
13.3.1 WELDING CURRENT
increasing current increases penetration and wire melt-off rate
(elding current effect on weld profile (/,= mm electrode diameter, *3 9 arc voltage
and -% cmBmin travel speed
excessively high current produces a deep penetrating arc with a tendency to burn-
through, undercut or a high, narrow bead prone to solidification cracking
excessively low current produces an unstable arc, lack of penetration and possibly
lack of fusion
13.3.# ARC &OLTAGE
Arc voltage adjustment varies the length of the arc between the electrode and
the molten weld metal. )f the arc voltage increases, the arc length increases and vice
versa. The voltage principally determines the shape of the weld bead cross section
and its external appearance.
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*3&A 3&&A -3&A
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Arc voltage effect on weld profile (/,= mm electrode diameter, 3&& A welding current
and -% cmBmin travel speed
)ncreasing the arc voltage with constant current and travel speed will;
produce a flatter and wider bead
increase flux consumption
tend to reduce porosity caused by rust or scale on steel
help to bridge excessive root opening when fit-up is poor
increase pickup of alloying elements from the flux when they are present
>xcessively high arc voltage will;
produce a wide bead shape that is subject to solidification cracking
make slag removal difficult in groove welds
produce a concave shaped fillet weld that may be subject to cracking
increase undercut along the edge(s of fillet welds
over alloy the weld metal, via the flux
+educing the arc voltage with constant current and travel speed will;
produce a CstifferD arc which improves penetration in a deep weld groove and
resists arc blow
>xcessively low arc voltage will;
produce a high, narrow bead
causes difficult slag removal along the weld toes
13.3.3 TRA&EL SPEED
)f the travel speed is increased;
heat input per unit length of weld is decreased
less filler metal is applied per unit length of weld, and conse2uently less excess
weld metal
penetration decreases and thus the weld bead becomes smaller
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/39 *39 =39
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Travel speed effect on weld profile (/,= mm electrode diameter, 3&& A welding current
and *39 arc voltage
13.3.' ELECTRODE SI(E
>lectrode si"e affects;
the weld bead shape and the depth of penetration at a given current; a high current
density results in a CstiffD arc that penetrates into the base metal. .onversely, a
lower current density in the same si"e electrode results in a CsoftE arc that is less
penetrating.
the deposition rate; at any given amperage setting, a small diameter electrode will
have a higher current density and a higher deposition rate of molten metal than a
larger diameter electrode. 7owever, a larger diameter electrode can carry more
current than a smaller electrode, so the larger electrode can ultimately produce a
higher deposition rate at higher amperage
>lectrode si"e effect on weld profile (-&& A welding current, *&9 arc voltage and ?-
cmBmin travel speed
13.3.) ELECTRODE E%TENSION
The electrode extension is the distance the continuous electrode protrudes
beyond the contact tip. At high current densities, resistance heating of the electrode
between the contact tip and the arc can be utilised to increase the electrode melting
rate (as much as /3-3&F. The longer the extension, the greater the amount of
heating and the higher the melting rate. (see below
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*&,3 cmBmin -% cmBmin %// cmBmin
*,/ mm =,& mm 3,&
mm
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13.3.* T+PE O$ ELECTRODE
An electrode with a low electrical conductivity, such as stainless steel, can with
a normal electrode extension experience greater resistance heating. Thus for the
same si"e electrode and current, the melting rate of a stainless steel electrode will be
higher than that of a carbon steel electrode.
13.3., WIDTH AND DEPTH O$ $LU%
The width and depth of the layer of granular flux influence the appearance and
soundness of the finished weld as well as the welding action. )f the granular layer is
too deep, the arc is too confined and a rough weld with a rope-like appearance is
likely to result, it may also produce local flat areas on the surface often referred to as
gas flats. The gases generated during welding cannot readily escape, and the surface
of the molten weld metal is irregularly distorted. )f the granular layer is too shallow,
the arc will not be entirely submerged in flux. 5lashing and spattering will occur. The
weld will have a poor appearance, and it may show porosity.
13.' STORAGE AND CARE O$ CONSUMABLES
.are must be given to fluxes supplied for #A( which, although they may be
dry when packaged, may be exposed to high humidity during storage. )n such cases
they should be dried in accordance with the manufacturerGs recommendations before
use, or porosity or cracking may result.
5errous wire coils supplied as continuous feeding electrodes are usually copper
coated. This provides some corrosion resistance, ensures good electrical contacts
and helps in smooth feeding. +ust and mechanical damage should be avoided in such
products, as they will both interrupt smooth feeding of the electrode. +ust will be
detrimental to weld 2uality generally since rust is a hygroscopic material (may contain
or absorb moisture and thus it can lead to hydrogen induced cracking.
.ontamination by carbon containing materials such as oil, grease, paint and
drawing lubricants is especially harmful with ferrous metals. .arbon pick-up in the
weld metal can cause a marked and usually undesirable change in properties. #uch
contaminants may also result in hydrogen being absorbed in the weld pool.
(elders should always follow the manufacturerGs recommendations for
consumables storage and handling.
13.) POWER SOURCES
)n arc welding it is principally the current which determines the amount of heat
generated and this controls the melting of the electrode and parent metal and also
such factors as penetration and bead shape and si"e. 9oltage and arc length are also
important factors with increasing voltage leading to increasing arc length and
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vice-versa. )n #A( welding usually a constant voltage (or flat characteristic power
source is used.
<ower can be supplied from a welding generator with a flat characteristic or
from a transformerBrectifier arranged to give output voltages of approximately %=-3& 9
and ranges of current according to the output of the unit these can be in excess of a
%&&& Amps.
The voltage-current characteristic curve is usually designed to have a slight
slope (see below
Volt-ampere curves of constant voltage (flat) characteristic
This unit will maintain an almost constant arc voltage irrespective of the current
flowing. The wire feed motor has an adjustable speed control with which the wire feed
must be pre-set for a given welding operation. 'nce pre-set the motor feeds the wire
to the arc at constant speed. 5or the arc to function correctly the rate of wire feed
must be exactly balanced by the burn-off rate to keep the arc length constant.
#uppose the normal arc length is that with voltage 9
:
indicated at : in the above
figure and the current for this length is )
:
amperes. )f the arc shortens (manually or
due to slight variation in motor speed to # (the voltage is now 9
#
the current now
increases to )
#
, increasing the burn-off rate, and the arc is lengthened to :. #imilarly
if the arc lengthens to 0, current decreases to )
0
and burn-off rate decreases and the
arc shortens to :.
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