Submerged Arc Welding
BY : KRUSHIL BHALANI, DIVAM BHALGAMIYA & RAJAN SINGH
S SUBMERGED
A ARC
W WELDING
CONTENTS
1 INTRODUCTION
4 ADVANTAGES OF SAW
2 PROCESS OF SAW
5 LIMITATION OF SAW
3 FUNCTION OF FLUX
6 APPLICATION OF SAW
INTRODUCTION
In the submerged arc welding process, the end of a
continuous bare wire electrode is inserted into a mound
of flux that covers the area or joint to be welded. An arc
is initiated and a wire feeding mechanism then begins to
feed the electrode toward the joint at a controlled rate. The
feeder is moved manually or automatically along the weld
seam. In mechanized or automated welding, the workpiece is
moved under a stationary wire feeder or the welding head
moves over the stationary workpiece.
Schematic Diagram of Submerged Arc Welding
The submerged arc welding, flux feeds
PROCESS OF SAW HOOPER through the hooper tube and
continously distributes itself over the
seam a short distance ahead of the
welding zone
WIRE FEEDING
The wire feed mechanism begins to feed
the welding into the joint at a controlled rate.
ARC INITITATION An electric arc is established as the current flows
between the electrode and the work.
TROLLY CAR The carriage is started either manually or
automatically to travel along the seam.
PROCESS PARAMETER
• CURRENT: The total welding current can range between 300 to 1500 amperes
• VOLTAGE: 20 TO 50 Volts
• Wires in one molten pool: from 1 to 6
• SPEED: 30-350 cm/min
• DEPOSITION RATE: 2-100 Kg/hr
• POLARITY: Like other wire-fed processes, DCEP polarity during the SAW process
provides optimal penetration. Conversely, DCEN increases deposition rates at the
expense of penetration.
FLUX
Flux is mixture of various minerals, chemicals, and alloying materials that primarily p[rotect the molten weld
metal from contamination by the oxygen and nitrogen and other contaminants in the atmosphere. The addition
of certain chemicals and alloys also help to control arc stability and mechanical properties.
When classified according to the manner in which they modify the composition of the weld metal, fluxes can
be categorized as
• Neutral fluxes
• Active fluxes
• Alloy fluxes
• Fused fluxes
• Agglomerated fluxes and bonded fluxes
• Mechanically mixed fluxes
• Crushed slag
• On the basis of Basicity Index
i. Acid fluxes ( BI < 0.9 )
ii. Neutral fluxes ( BI 0.9-1.2 )
iii. Basic fluxes ( BI > 1.2 )
Funtion of FLUX
HELPS ARC SHAPING PREVENT CONTAMINATION
To assist arc striking and To form a gas shield to
To form a slag that will
stability protect the molten filler
protect and influence the
shape of the weld bead. metal being projected across
the arc gap
SOLIDIFICATION CHEMICAL REACTION EASE REMOVAL
Flux must possess a melting Due to chemical reactions Flux should promote the slag
temperature lower than between flux(slag), arc detachability and arc
1500°C so that the weld plasma, and weld pool, the stability.
metal (WM) solidifies before flux formula should be fine-
the molten slag does. tuned to properly control
WM composition.
Note : Flux must satisfy physical and chemical properties to ensure the quality of saw process
Advantages of SAW
• As the arc is completely submerged in the granular flux, therefore no spatters.
• Fumes are not generated.
• Ultraviolent radiation will be suppressed.
• This process can be made semi-automatic and fully automatic.
• This method can be used for both indoor and outdoor applications.
• High quality and productivity.
• High deposition rates are possible.
• At least half or more of the flux is recoverable.
Limitation of SAW
• Limited to flat welding position.
• With modern tools and fixtures, it is limited to the horizontal
position.
• Limited to nickel, steel and stainless steel.
• The process requires more training from its operators given greater
complexity and control of the process.
APPLICATION OF SAW
Pressure vessel Automotive and aviation Shipbuilding
• Welding low carbon and low alloy steel.
• Automotive, aviation and shipbuilding.
• In pipeline construction, submerged arc welding is widely used for welding long sections of pipe together.
• Additionally, submerged arc welding is also used in the manufacturing of heavy equipment such as cranes, bulldozers,
and excavators.
THANK YOU
