Welding Processes 11

MMA welding technique can also be used for improving surface properties of
certain components like resistance to friction, wear, impact, abrasion, erosion,
oxidation and corrosion. In such cases surfacing electrodes - also known as hard
facing electrodes—are used as the filler rod. This technique can also be used for
building of worn—out components.
Submerged arc welding (SAW)
Submerged arc welding is a method in which the heat required to fuse the metal
is generated by an electric current passing through between the welding wire and
the work piece. The tip of the welding wire, the arc and the weld area are covered
by a layer of granular flux. A hopper and a feeding mechanism are used to provide
a flow of flux over the joint being welded. A conveyor tube is provided to control
the flow of the flux and is always kept ahead of the weld zone to ensure adequate
supply of flux ahead of the arc.
Figure 1.7 shows a typical SAW process. The intense heat evolved by the passage
of the electric current through the welding zone melts the end of the wire and the
adjacent edges of the work pieces, creating a puddle of molten metal. The puddle
is in a liquid state and is turbulent. For this reason any slag or gas bubble is quickly
swept to the surface. The flux completely shields the welding zone from contact
with the atmosphere. SAW can use much higher heat input and has slower
solidification and cooling characteristics. Also the silicon content will be much
higher in submerged arc welding, if care is not exercised in selecting proper flux
material. SAW can be used for welding of materials in higher gauges.
SAW has the advantage of high weld metal quality and smooth and uniform
weld finish. Deposit rate, deposition efficiency and weld speed are high. Smoke
and arc flash are absent in SAW. The operator's skill is minimum in SAW and it is
extensively used in heavy steel plate fabrications.

Fig. 1.7 Submerged arc welding

(Courtesy: Welding Hand Book @ AWS, USA, 1966)