WELDING
Welding is an industrial art of joining metals
Welding is a process of metal joining
by applying heat and some times
pressure
Classification of welding processes
welding
Forge or Pressure Fusion or non pressure
Welding welding
( Under pressure without ( With additional filler
additional filler metal ) metal )
Forge or Pressure welding :- The work piece are heated to plastic state & then work
pieces are joined together by applying pressure on them. In this case no filler material
is used.
Fusion or non- pressure welding :- Here edge of work piece to be joined & filler materia
both are heated to a temp. above the melting point of the metal & then allow to solidify
Forge or pressure
welding
Welding heat created by
Furnace Electric current
friction
Forge or furnace welding Resistance welding friction welding
Spot seam projection flash butt
Fusion or non
pressure welding
Welding heat created by
gas Electric Arc chemical
reaction
Oxy-acetylene welding Thermit welding
Consumable Non Consumable
electrode electrode
plasma arc Carbon TIG
Shielded metal arc atomic hydrogen submerged arc
arc
MI electro Flux
G slag cored
Other processes of welding
are :
Solid State welding : The solid state welding depends upon the theory
that if two perfectly clean metallic surfaces are placed in an intimate contact ,
the cohesive force between atoms of the two surfaces is sufficient to hold them together.
The various solid state welding process are:
Friction Welding
Ultrasonic Welding
Diffusion Welding
Explosive Welding
Modern Welding Processes: Electron Beam Welding
Laser Beam Welding
SAW
Submerged
Arc Welding
Introduction
⮚ Submerged arc welding (SAW) is a method in which the
heat required to fuse the metal is generated by an arc formed
by an electric current passing between the electrode and the
workpiece.
⮚ There is no visible arc and no sparks, spatter or fume. The
electrode may be a solid or cored wire or a strip.
⮚ SAW is normally a mechanised process.
GENERAL SCOPE
⮚ Current: the total welding current can range between
100 and 3600 amps.
⮚Wires in one molten pool: from 1 to 6.
⮚Voltage: 20-50 volts.
⮚Speed: 30-350 cm/min.
⮚Deposition rate: 2-100 kg/hr.
EQUIPMENTS
Hopper
Flux Power Source
Wire +
+ –
Slag
Flux Base Metal
Wel • Arc
•••••••••••• •
d ••
• •
•
SAW
PROCESS PARAMETERS
⮚ Current
⮚ Voltage
⮚ Travel speed
⮚ Size of electrode
⮚ Stick-out
⮚ Heat input rate
Effect of
current
Bea
d Penetrati
widt on
h
Current Curren
t
400 A 550 A 700 A 900 A
Effect of
Voltage
Bea
Penetrati
d
on
widt
h
Voltag Voltag
e e
28 V 34 V 38 V 42 V
Influence of Amperage and Voltage
Higher amperage gives deeper penetration
Higher voltage gives wider penetration. The arc
length gets extended
Effect of welding
speed
Bea
d Penetrati
widt on
h
Weldin Weldin
g g
speed speed
Effect of stick
out
40 50 30
Ø 4 mm ; 650 A ; 32 V ; 550 mm / min
Influence of stick-out
Longer stick-out gives higher deposition rate, but also
more shallow penetration.
Above: Penetration at different stick-out
Right: Deposition rate at different stick-outs.
A: 25 mm
B: 57 mm
C: 83 mm
Effect of polarity
+ ~ -
DC + AC DC -
Influence of polarity and wire diameter
Deepest penetration with positive electrode. Normally, the
welding machine is equipped with DC positive electrode.
At constant amperage, the penetration gets deeper with
smaller wire diameter, due to the higher current density.
Typical Welding
Parameter
Sr Voltage Speed Dep. Rate
Current A
Wire
no Ø mm V mm/min Per Arc Hr
1 1.6 200-300 22-26 750-1500 3 – 4 kgs
2 2 250-350 24-26 750-1250 3- 4.5 kgs
4 2.5 300-350 25-27 750-1250 4 –4.5 kgs
5 3 400-500 28-30 500-750 5 – 5.5 kgs
6 4 550-650 30-32 400-750 5.5 - 7 kgs
7 5 600-800 30-34 350-750 6-8
kgs
SUBMERGED ARC WELDING
CONSUMABLES
FILLER MATERIALS SAW FLUXES
Wire / Solid electrodes
Fused fluxes
Cored wires
Agglomerated fluxes
Strip electrodes
Metal powders
Types Of Flux
• Fused
Flux
• Agglomerated Flux
»
Neutral Flux
»
Active Flux
»
Alloy Flux
Neutral , Active And Alloy Fluxes
❖ Neutral fluxes :
These fluxes do not produce any
significant change in the weld metal
chemical composition due to a large
change in arc voltage or arc length /
stick out.
❖ Active fluxes :
These contain manganese and /
or silicon bearing ingredients as de-
oxidiser and changes the weld metal
chemical composition with change in
arc voltage / stick out.
❖ Alloy fluxes :
contain alloying ingredients in
the flux and when used with non –
Basicity Index ( B.I )
■ B.I = BASIC OXIDES / ACIDIC OXIDES =
■ [CaO+MgO+Na2O+CaF2+1/2(MnO+FeO)]
■ ------------------------------------------------------------
----
■ [SiO2+1/2 (Al2O3+TiO2+ZrO2)]
■ B.I < 0.9 , ACIDIC
B.I = 0.9 to 1.2 , NEUTRAL
B.I > 1.2 -2.0 , BASIC
B.I > 2.0 , HIGH BASIC
Function Of Flux
In SAW
• Stabilizes Arc
• Cleans the weld from unwanted impurities
• Increases Fluidity of molten metal
• Forms slag after melting & covers weld
• Allows deposited metal to cool slowly
• Compensates alloying elements Within the weld
• Eliminates spatter generation
• Helps in even & uniform bead finish
Why Baking
Flux?
• To remove the moisture (H2O)
• To avoid possible cracking of weld due
to H2
Baking Requirements
For Flux
• Spread the loose Flux in a Tray Of baking Oven
• Identify The Tray With The Quality/Grade Of Flux
• Bake Tray in an Oven Between 300° C to 350° C
• Baking Time 2 Hrs to 3 Hrs
• Reduce the temperature to Min 100 ° C
• Hold the Flux at this temperature till use
TYPES OF SAW
Single Wire
Twin Wire
Tandem
Tandem Twin
Multi wire
Submerged Arc
Welding
Advantages
■ High deposition rates
■ No arc flash or glare
■ Minimal smoke and
fumes
■ Flux and wire added
separately - extra
dimension of control
■ Easily automated
■ Joints can be prepared
with narrow grooves
■ Can be used to weld
carbon steels, low alloy
steels, stainless steels,
chromium-molybdenum
steels, nickel base alloys
Submerged Arc
Welding
Limitations
■ Flux obstructs view of
joint during welding
■ Flux is subject to
contamination ⇒
porosity
■ Normally not suitable
for thin material
■ Restricted to the flat
position for grooves -
flat and horizontal for
fillets
■ Slag removal required
■ Flux handling
Application of SAW
This welding method can be used for:-
⮚Fabrication of Boiler Pressure Vessel.
⮚Railroad tank cars.
⮚Structural shapes and cylinders.
⮚Circular welds.
⮚Beam Production.
⮚Ship Building.
⮚Circumferential welding in wind tower fabrication.
⮚Longitudinal pipe welding.
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