SAW Process

technik
 SAW Process Principle

Arc between Electrode & Base Metal

Arc submerged under blanket of Flux
Mechanized Wire Feed
Mechanized Travel
Welding Operator monitors & controls
welding parameters
 SAW PROCESS

Wire and Flux Combination

Submerged Arc
 Depth of Fusion for SAW

The depth of fusion can be varied from

2 mm to 12 mm
This is possible by varying current
density,current type, electrode
polarity,current level,welding speed,
molten pool depth below the arc, arc
oscillation, electrode inclination and bead
overlap
 Factors affecting Depth of fusion

Current Density -Amps / mm2

Current Type - AC / DC

Electrode Polarity -DCEP / DCEN

Current Level Amps

Welding Speed -mm / min

 Factors affecting Depth of fusion

Molten pool depth mm

Arc Oscillation - frequency, width , dwell times

Electrode Inclination - degree , leading / trailing

Bead Overlap - %
 Deposition Rate for SAW

The deposition rate can be varied from

2 kg/ arc hr to 30 kg. / arc hour
This is possible by process variations
involving electrode size, type, number,
power, polarity and stick-out
Factors Affecting Deposition Rate

Electrode Size mm dia. / mm thick x mm wide

Electrode Type - wire / strip
Electrode Nos - single / twin / two / multiple
Electrode Power DC / AC
Electrode Polarity - DCEP / DCEN
Stick out - mm
Weld Groove Designs for SAW

Lower end of thickness .

Square groove with zero gap
Weld Groove Designs for SAW

Intermediate range of thickness

Single / Double / Compound Vee with
included angle between 60 to 16 degrees
Weld Groove Designs for SAW

Higher end of thickness

Machined U / J groove with joint gap
between 18 to 22 mm and
included angle between 10 to 2 degrees
Welding Positions for SAW
Mechanization for SAW
Relative motion between weld joint and
welding head
Joint Tracking
Visual and Manual by operator
or
Automatically using mechanical / optical /
laser probes in combination with servo motor
operated cross slides
Electrodes for SAW

Round Electrodes - 0.8 mm to 6.4 mm

Flat Strips - 0.5mm thick, 30to150 mm wide
Type- Solid / Flux-cored
Number- Single / twin / multiple
Power DC / AC
Electrodes for SAW

Contact tip- Common / Independent / Series

Polarity Positive / Negative
Oscillation- Yes / No
Position- Inclination / Direction / Spacing
Fluxes for SAW

Mfg. Method Fused / Agglomerated

Type Neutral / Active / Alloying
Suitable for CS, LAS , SS , Ni , Ni alloys
Basicity Acidic / Semi Basic / Fully Basic
Usable with single / twin / tandem / strip
Fluxes for SAW

Max. welding speed -500 to 2500 mm/min

Welding Power AC / DC
Max. Current 800 to 1500 Amps
Resistance to Porosity
Max. Hydrogen Content- 5to20 ml / 100gms
Max. attainable weld metal toughness
 Conventional SAW
Electrode 3.15-6.3 - 3.5 to 12 mm in single
Dia. ( mm) pass
Current 400-1200 - 6 to 16 mm in two
( Amps ) passes
Deposition 4 -20 - >15 mm in multi-pass
Rate - 3 to 12 mm leg fillets in
single pass
( kg/H)
- Surfacing tolerating 30
Welding 200 -1500
to 60 % dilution
Speed
(mm/min)
 Thin Wire SAW
Electrode 0.8-2.4 - 2.5 to 6 mm in single
Dia. ( mm) pass
Current 150-600 - 3 to 12 mm in two
( Amps ) passes
Deposition 2 -10 - 6 to20 mm in multi-pass
Rate - 3 to 12 mm leg fillets in
single pass
( kg/H)
- Surfacing tolerating 20
Welding 100 -1000
to 30 % dilution
Speed
(mm/min)
 Twin Wire SAW
Common Contact Tip & wires aligned along the weld joint

Electrode 2.0-2.4 - >20 mm in multi-pass

Dia. ( mm) - Large fillets in single
Current 800-1000 pass
( Amps )
Deposition 12 -20
Rate
( kg/H)
Welding 400 -1500
Speed
(mm/min)
 Twin Wire SAW
Common Contact Tip & wires aligned across the weld joint

Electrode 2.0-2.4 - Surfacing

Dia. ( mm)
Current 500-800
( Amps )
Deposition 6 -12
Rate
( kg/H)
Welding 200 -500
Speed
(mm/min)
 Multiple Wire Tandem SAW
Two Electrodes
Electrode 4 - 6.3 - Welding of pipes /
Dia. ( mm) plates in minimum passes
Current 800-1500 6 to 25 mm thick
( Amps ) -
Deposition 20 -40
Rate
( kg/H)
Welding 600 -2000
Speed
(mm/min)
 Multiple Wire Tandem SAW
Three Electrodes
Electrode 4 - 6.3 - Welding of pipes /
Dia. ( mm) plates in minimum passes
Current 800-1500 15 to 40 mm thick
( Amps )
Deposition 30 -60
Rate
( kg/H)
Welding 1000-
Speed 3000
(mm/min)
 Strip SAW
Electrode 0.5 X 30 - - Surfacing
Size ( mm) 125
Current 400-2000
( Amps )
Deposition 7.5 -30
Rate
( kg/H)
Welding 200 -600
Speed
(mm/min)
 Narrow Gap SAW
Electrode 3.15-4.0 - Welding of thick joints
Dia. ( mm) up to 300 mm thick with
Current 500-650 joint gap of 18 to 20 mm
( Amps )
Deposition 5 -8
Rate
( kg/H)
Welding 350 -500
Speed
(mm/min)
 SAW APPLICATION

Tractor Mounted Welding Head

Cross Beam Mounted Welding Head

 SAW APPLICATION

Welding Head Motion by Column & Boom

SAW APPLICATION

Job motion by Rotator

SAW APPLICATION

Job motion by Positioner

SAW APPLICATION

Job motion by lathe

 SAW APPLICATION

Job motion by conveyor

SAW APPLICATION

Weld Overlay using thin wire

SAW APPLICATION

Weld Overlay using Strip