TWI

voot

THE-WELDTNG NSTmUTE

SECTION13

T\vI

700t

TIIE \VEIDING

Ir\ STN-LII-E

A ',FL AT 'A RC P RO CE SS(C ON ST A N TVOL

)
TAGE

SUBMEBGED-ARC
(SA)

Typicaldefectsassociated
with this
process:
Porosity.
Cracking.
o S l a gi n c l u s i o n s .

Type of Operation
Mechanised,
automaticor semi-automatic. . Incompletepenetration.
Modeof Operation
Excessivepenetration.
An arc is maintainedbetweenthe end of a
barewire electrodeand the work-As the
Weld profiledefects.
electrodeis melted,it is fed intothe arc bv
a set of rolls,drivenby a governedmotor.
. undercut
Wire feed speedis automatically
controlled
to equalthe rateat which the electrodeis
Lackof fusion.
melted,thus arc lengthis constant.
The arc
operatesundera layerof granularflux
(hence'submerged,arc).Someof the flux
meltsto providea protectiveblanketover
the weld pool; the remainderol the flux is
unaffectedand can be recovered
and
re-usedprovidedit is dry and not
contaminated.
A semi-automatic
versionis available
in
which the operatorhas controlof a
weldinggun which carriesa smallquantitv
of flux in a hopper.

WELDING TECHNOLOGY
lssue O191

13.1

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,t/i8
S U B M E R G E DA R C W E L D I N G :
PROCESSAND EOUIPMENT
FUNDAMENTALS
The principreof tne submerged-arcprocessis shownschemaircary
beiow. A
power sourceP, is connectedacros-s
the contectnozzteon tne werdinci.p".
and the workpiece.The powersourcecan be a transformer
fof AC *J,oi.g'",.
a rectifier(or motor generator)for DC werding. The firer materiars
are an
uncoatedcontinuouserectrode
and a granurarwerdingflux fed down to rne
joint by way of a hose from the flux hopper. To prevJnt
tne electroOe
overheatingat high currentsthe weldingcurrent is transfened to
the electrode
ar a porntvery croseto the erectricarc. The arc is burning in a cavity
filJed
with gas (cor, co, etc) and metal fumes. In front the cav-ityis warteo
in oy
unfused parent materiar,and behindthe arc by soridifyingwerd
metar. The
covering over the cavity consistsof mortensrag. The diagram
berowaiso
shows the solidifiedwerd and the thin coveringof soridsrJg which
has ro oe
detached aftef the completionof each run.

C.orlti,iEqr

3;Jir.d

Er.

.h<.rd.

W.ld c@l

since the arc rs compretely

submergedby the fruxthere is none of the initating
arc radiatjonwhich is so characteristic
of the open arc processes;werding
screensare thereforeunnecessary.
The weldingflux is nevercompletelyconsumedand the surplusquantity
left
ca,'l be collectedeither by hand or automatjcallyand returned
io the flux
h o p p e rt o b e u s e da a a i n .

ll.z

WELDING TECHNOLOGY
lssue 0191

cI

T\vI

THE WETTING [\iSf|T]]-IT

Althoughsemi-automatic
submerged-arcweldingequipmentexists
and is
convenientfor certainapplicationsl
most,of ttresJomerieo-arJrietoing
carriec
out today makes use of fullymechanised
tne majn virtuesof the submerged-arc weldingequipment.lndeed,one of
processis the ease withwhjch it
can
be incorporated
into fu,y r""nlnlJ
*erding.systemsto give high deposrtion
rates and -::l:l"i,t
weld quaiity. Welo metatrecovery
approachest0O%
since losses throughspatte'rare
exremety smat. Heat rossesfrom rne
arc are
aiso quite low..gwingto the insulating-effect
of the flux bed, and for this reason
the therma, efficiencyof the submeri"o_"r"
pro""." can be as hign as 60%
compared with about 2s/" for manuij
metatja;a"MA) ;;;s.,,,
FIux consumptionis approximately
equal to the wire consumption,the
actual
ratio_ weishtof wireconsumeo:

weiqhiorftil;;;;;;:'
on the flux type and the weldingpara"merers
useo.

#i;

aepenoent

werdingparameters
are maintained
at theirset varuesby the arc conrrorunit.
A feed-backsystemis usuatyusedto
maintain" "tJr"'"r"l.iiri
.o ,nu, "
changein the ar^clength,_corresponJing
ro
u
change
_ will
in
arc
voltage
producean increaseor decrease
in the wirefeedspeeduntirthe originalarc
tengthis regained.
Joint preparation
Joint preparation
dependson plate
'and thickness,
andtypeof joint,e.g.
circumferentiar
or rongitudinar, to somee:tent,on
the standardsto which
the structure
is beingmade.
Pratesof up to.14mmthickcan be butt
werdedwithoutpreparation
wrtha gap
not exceeding
or 10% of tne prail inicr<ness,
whichever
is the ore:rer
Thicker
pr",". ]m1
iirrriip-enetration
is
to
be
obtained.
v:r1"rl"
fitupcannotbe1^:lllparation
tolerated.
A wetder,.'"n.:l:l:::tr:d_..
to copewith varyins
:an adjusthis technique
'a'j:::",?"#.1tf::l ru"". or varvins
dimensions.Not so an automaticweldins

"JffJL[::1'
";j*
;
o
r
3
m
m,
r,
'"*ii"d'il
:on,
:,::,'ilT"H;
li
ru.
*"
such circumstances
a hand-wetoeo
rooirun usingMrGor MMAerectrodes
is

advisable. All plate edges must O"

"U"of rt"fy

clean and free from

mi|scare,paint
rflmpuritiesare prl-s"nt*o are meltedinto rust, oil,
the werd,
.etc-_can easily
porosityand cracking
occur.

Time spent'n
suchdefectsby caretutjointpreparation
and
T,1,1:l.nn
thoroughinspection
priorto werdingis tirirewe, spentsince
cuttingout werd
defectsand then reweldingi, u".yirl"n"ive
andttme_consumino
WELDINGTECHNOLOGY
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TllE WELDINGL\sTriuTE '

Weldingprocedure
tn generarthe moreseverethe requirements
regardingrowtemperature
notch
toughnessthe lowerthe maximumweldingcurrentthat can be used
to
minimiseheatinput,whichmeansthat a multipasstechnrqueis ca.Ied
for.
when werdingstainress
steersthe heatinputshourdbe keptrowfor other
reasons:stainress
steelhas poorthermajconductivity
and a highcoefficient
of
expansioncomparedwith mirdsteer. Thesetwo effectsreadto overheatino
and excessivedistortionif largediameterwiresand highcunenti
;";";;:
Multirunweldsusingsmalrdiameterwiresare thereforerecommended
for
stainlesssteelsand highnickelalloyssuch as Inconel.
Selectionof weldingconditions
selectionof the correctwerdingconditions
for the pratethicknessand joint
preparationto be weldedis very importantif satisfactoryjoints free
from
defectssuch as cracking,porosity,and undercutare to be obtained.The
processvariableswhichhaveto be considered
are:
electrodepolarity
weldingcurrent
c . electrodediameter
arc voltage
weldingspeed
f. electrodeenension
s. electrodeangle
h . flux depth
h

These are the variableswhich determinebead size, bead shape,

depth of
penetration,and, in some circumstances,metallurgical
effectssuch as
incidenceof cracking,porosityand weld metal coriposition.
a.

electrodepolarity

The deepest penetrationis usuafiyobtainedwith Dc reverseporarity(erectrode

+ve) which a.lsogives the best surfaceappearance,beao shape, and
reststanceto porosity.
Direct current straightporarity(erectrode-ve)gives faster burnoff (about
35%)
and decreasedpenetrationsince the maximumheat is deveroped
at the tip of
the electrodeinsteadof at the surfaceof the prate. For this reason
DC-ve
polarityis often used when weldingsteels of ljmitedweldability
and when
surfacingsince, in both instances,penetrationinto the parent material
must be
kept as low as possible. The fluvwire consumptionratio is less with electrode
-ve polaritythan with electrode
+ve so that alloyingfrom the flux is reduced.

13.4

WELDING TECHNOLOGY
Issue 0191
,

rI

T\vI

WE

l-HE \i ELDINC i\.STflf_t

In changingfrom erectrode+ve to -ve porarity

some Increasejn arc voitace
b: necessaryto obtajn" "ornp.ruti" Ouuo
"nup". ,eltematrng
T"l a
";;;, ',.
grves
resultabouthalf way betweenDC electrode
*u",n.r _"" ,i.';;,":

particutarty
usetul
whenarc'blow
is a prolrem-J:".J-""il;r;;:ff::_

sysrems,where a DC +ve electrodeis used

as tne leadjnge]ectrode;; ;
AC electrodeas the trail
b.

5,:

welding current

Increasingthe wire feed speed increases

the werdrngcurrentso that the
depositionrate incfeaseses the werding
"rrr.liin"r.u"es.
The current
densitydeterminesthe O.jrl^"t_,?:l.j*ion:
tne nign.r' ,n. currentdensity the
greater the penetration. For a given
flux, arc stalitity w* be rost below a
mrnimumthreshordcurrent deniity so that
if tne cuirent for a grvenerectrode
.rameter is too row arc stabirityis rost
and a russed rnegurarbead is obtained.
Too high a current densityalso reao" to
in"troiiiT-i"."r." rne erectrode
overheals. Undercuttingmay also occur.
c.

electrodediameter

current, changingthe electrodediameterwiil

changethe current
l::_9::""
density,which means in oracticethat a
larger diameterwill reduce penetiation
and the liketihoodof burnthrough,but at th;-;;
ile arc stnkingis more
difficultand arc stabilityis reduced.
o.

arc voltage

"{:O of arc voltage is often misunderstood

becauseif affectsdilution
1:
rather than penetration. Bead_on_plate
wetOsanJ square edge close butt
welds (no gap) have increasedwidtn and
dirutionas arc vo[age increases,but
depth of penetrationremainsthe same.

E tfrt

ol.-c

ta/q.

c.1b.d r\.-.

WELDING TECHNOLOGY
Issue 0191
t5 c

T\^/I
voTN
rlJlJy

'n1E

wa1p1\.'c i\-STi]l_tT

lf the joint is ,open,,* f':r^ilrnil:

in a butt jojnt with raiher smalt anqted
preoaration,increasrngthe
V
arc voltage c_andecrease the penetratjon.
lncreasingthe arc voltaqe lengthens
the arc so thal weld bead wjdih js
increased, reinforcemenlis
de-creased,
ir* """*"

probabir*v
orarcbrow-is
arso
increased.
*n"" ",,ifil"J,iJrli?T?,Li'rj."'r"
length and hence

arc voitag:,is u",y importani',;;;"

" hrgharc voltagesmore
flux is meitedso that more ajloying
elements.nGi rn" weld rnetal.
Tnus arc
vottageca,l affect weld merar
composition
e.

welding speed

Beadsize is inverselypril"T]?11
ro weili1o speed.
penetration
and beadwidth,increasetne titJtinooo Fasterspeedsfeduce
of porosityand,if takento
the eltreme,produceundercuning
*d irr{;l;;;l"or.
ot highwetding
the arc volraseshoutdbe keptfr;;l;;
Ji.,i*,.u
arc btowis riketvto
;:ff:.
lf the weldingspeedis too slowburn-through
c3n occur. A combination
of
high arc volLage
and stowwelding"p";;;
p;,-ile
a
mu.nroom_shaped
weld beadwith solidification
cracis at the beaOside!.

f.

electrodeextension (stickout)

Electrodeextensionis an important
variablesince
- it governsthe arnountof
resistanceheatingwhich occurs
in the erectrod". ii tn" eltension is
short the
neatingeffectts smallanc

jjtJ;,[.J,.::::,T:;$T:j?:,
increaies,n"t",p",.",i.".,.Ti;t:":i1,..?,

Deposition
rateis increased.IncreaseJ;;";;i;;
therefore
usefutin
and surfacingapplications
Ort .i"p. r,"""'io oe takento guidethe
:i::jig
etectrode
otherwise
it wanders

ror normarwerding
the erectrode
enensionshourdbe 25-3ommfor mildsteer
and ratherress'say 2o-25mm'for
stainless.rni. i, o".uure the erectrical
sensitivityof starnless
wireis appreci"'v gi".i"i ih"n thatof
mildsteelwire.
1? A

WELDINGTECHNOLOGY
lssueOl9l

T\vI

w[f

TT WEI.DINGU\STTTUTE

S.

electrodeangle

since the angiebetweenthe eiectrode

and the piateoetermines
the pointof
appiicationand directionofrhe arc
i"."-it
n*
J'p'rJtorno
effect
on both
penetrationand undercut. The-trgures
.noru
,.r"Jt;"t
on
horizontalfuerticaJ
,
fiiretwerds,and comparethe efreit obtai;;J
"i,r "'iu.t,".r arc withthose
andtraiting

arcs.rhe-"#"rt-""undercuttins
canbe

;:liffX,;Hjgadins

EqJd Lf t r!d!

Oa.9-t

F,ll

lddr

Hin.
'f.nd.icy

tur

ts qx,..dn:

s-rn

El{<1 ol .tadd.

Mod...r.
trlt.:

Irl H V nkt

..id..lb,

Urc F,ld-

WELDINGTECHNOLOGY
IssueOfgl
. 1i.2

T\4/I

I}{E-i4Ii)tNc

h.

n\slm,t:

ftux depth

The fiux burden or the

simp,vheaped; u;;,["'.[:jJEH:ff [":j il::::,fl:_f"j: yi;ffi

"_

resurtsare to be obtainedthe flux

oeptnsrrou-ri-oe
just sufficientto coverthe
arc' arthoughat the pointwherethe
erectrode
"nte..stn" fruxbedrightrefrected
rromthe arc shouldjust.bevisibre.
roo "r'urL* "
b:d givesflash-through
and can causeporosity
ryl
ot
inaOequate'mlbllurgical
protection
-b:?r"g
moten metal. Too deeo
a flux.bedgiu"a;*or." oeaoappearance of the
and can
leadto spitageon circumferentiaL;;rd;.il;;
preparations
in
thick
prateit
important
t::".,! """"."iu.-nr"-i!itn otr.,"nn
:"|:l':!lyty
i"e
the
weld
snape and slag removalcan be
beao
unsatisfactorv.
Strip ctadding
Althoughmost appticatioT-:1.!_"
"yOrerged arc processmakeuse of
sinole_
or murtiwiresystemsusinground
wires,eiectrodeJintn" form a strip ar"
usedfor ctaddingpurpose-s.
o-ften
strpsare'usJ;iift;r,
thick,the commonest
skip widthbeins60mm.b_t1l^li!:r
"qp"1;.; ioom can be usedwithout
lossof quality. The biq a
anv

jrrvuiinil"t",fl
,*1",j;nij;,il'
particu
::"5:o:r,.",1u:lff
fl
:;J:,ffi
hish. Modem ftuxesdesisnel f.::!l"t

srearercurrenttolerance
than earliertypes and use of currents if:iddi;;;;;
or
up
to
izboA
with
austeniticstainress
steelstripsgivesdepositio:
o{.uq
to
Z2mglhr
with
DC
etectrode+ve
polarity.lnconelcan also -.i""

jffi
jt;,:""l,sJ,t
;#ii{l!"fl
,1u:511
1_dl1"r:i;;H;ffi
,iH
can be obtained.Monet,atuminium
b.;",;;k;i
ano .,rzci. stripshave
arso

Deensuccessfuily
,.._g stripcraalinger;;i;"".
contactbetweenthe strip and- feed'nozzle
i"-"."-.]i'tl,.

13.8

Goodetectrical

WELDINGTECHNOLOGY
Issueolgl
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TWI

ZZry
T}IE \4'EI.DING OVSTJ-n,"IE

QUESTIONS:
SUBMERGEDARC WELDING
(SAW)

Ql

. What are the weldingparameters

in SAW?

Q2

03

State three (3) itemswhichcontrol

weld metajcompositionin SAW.

Statethree(3) itemsof a flux

whichrequireinspection.

Q4
,.""ffffiJ:,

Q5
il:.*
a)
b)
c)

tvpesof a fluxusedin sAWandgive

briefdetairs
of

advantageand applicationfor
each of the
DCVe+
DCVeAc

QSle

foltowingpower