Welding Inspector

Submerged Arc Welding Section 13

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Submerged Arc Welding Introduction

Submerged arc welding was developed in the Soviet Union during the 2nd world war for the welding of thick section steel.
The process is normally mechanized. The process uses amps in the range of 100 to over 2000, which gives a very high current density in the wire producing deep penetration and high dilution welds. A flux is supplied separately via a flux hopper in the form of either fused or agglomerated. The arc is not visible as it is submerged beneath the flux layer and no eye protection is required.

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SAW Principle of operation

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Principles of operation
Factors that determine whether to use SAW chemical composition and mechanical properties required for the weld deposit thickness of base metal to be welded joint accessibility position in which the weld is to be made frequency or volume of welding to be performed

SAW methods

Semiautomatic
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Mechanised

Automatic

Submerged Arc Welding

Filler wire spool Flux hopper Power supply

+ Slide rail

Wire electrode Flux

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SAW process variables

welding current current type and polarity welding voltage travel speed electrode size electrode extension width and depth of the layer of flux

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SAW process variables

Welding current controls depth of penetration and the amount of base metal melted & dilution

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SAW operating variables

Current type and polarity Usually DCEP, deep penetration, better resistance to porosity DCEN increase deposition rate but reduce penetration (surfacing)

AC used to avoid arc blow; can give unstable arc

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SAW Consumables
(Covered in detail in Section 14)

Fused fluxes advantages:

good chemical homogeneity easy removal of fines without affecting flux composition normally not hygroscopic & easy storage and handling readily recycled without significant change in particle size or composition

Fused fluxes disadvantages:

difficult to add deoxidizers and ferro-alloys (due to segregation or extremely high loss) high temperatures needed to melt ingredients limit the range of flux compositions
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SAW Consumables
Agglomerated fluxes advantages: easy addition of deoxidizers and alloying elements usable with thicker layer of flux when welding

colour identification

Agglomerated fluxes disadvantages:

tendency to absorb moisture

possible gas evolution from the molten slag leading to porosity

possible change in flux composition due to segregation or removal of fine mesh particles
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SAW equipment
Power sources can be: transformers for AC transformer-rectifiers for DC

Static characteristic can be:

Constant Voltage (flat) - most of the power sources Constant Current (drooping)

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SAW equipment
Constant Voltage (Flat Characteristic) power sources: most commonly used supplies for SAW can be used for both semiautomatic and automatic welding

self-regulating arc
simple wire feed speed control wire feed speed controls the current and power supply controls the voltage applications for DC are limited to 1000A due to severe arc blow (also thin wires!)

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ARC CHARACTERISTICS
Constant Voltage Characteristic

OCV
Large arc gap Small arc gap

Small change in voltage = large change in amperage

Volts

The self adjusting arc.

Amps
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SAW equipment
Constant Current (Drooping Characteristic) power sources: Over 1000A - very fast speed required - control of burn off rate and stick out length can be used for both semiautomatic and automatic welding not self-regulating arc must be used with a voltage-sensing variable wire feed speed control more expensive due to more complex wire feed speed control arc voltage depends upon wire feed speed whilst the power source controls the current cannot be used for high-speed welding of thin steel

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SAW equipment
Welding heads can be mounted on a: Tractor type carriage provides travel along straight or gently curved joints can ride on tracks set up along the joint (with grooved wheels) or on the workpiece itself can use guide wheels as tracking device due to their portability, are used in field welding or where the piece cannot be moved

Courtesy of ESAB AB

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Courtesy of ESAB AB

SAW operating variables

Welding current too high current: excessive excess weld metal (waste of electrode), increase weld shrinkage and causes greater distortions excessively high current: digging arc, undercut, burn through; also a high and narrow bead & solidification cracking too low current: incomplete fusion or inadequate penetration excessively low current: unstable arc

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SAW operating variables

Welding voltage
welding voltage controls arc length increase in voltage produce a flatter and wider bead increase in voltage increase flux consumption increase in voltage tend to reduce porosity an increased voltage may help bridging an excessive root gap an increased voltage can increase pick-up of alloying elements from an alloy flux
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SAW operating variables

Welding voltage

low voltage produce a stiffer arc & improves penetration in a deep weld groove and resists arc blow excessive low voltage produce a high narrow bead & difficult slag removal

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SAW operating variables

Welding voltage excessively high voltage produce a hat-shaped bead & tendency to crack

excessively high voltage increase undercut & make slag removal difficult in groove welds
excessively high voltage produce a concave fillet weld that is subject to cracking
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SAW operating variables

Travel speed increase in travel speed: decrease heat input & less filler metal applied per unit of length, less excess weld metal & weld bead becomes smaller

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SAW operating variables

Travel speed excessively high speed lead to undercut, arc blow and porosity

excessively low speed produce hat-shaped beads danger of cracking excessively low speed produce rough beads and lead to slag inclusions
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SAW operating variables

Electrode size
at the same current, small electrodes have higher current density & higher deposition rates

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SAW operating variables

Electrode extension
increased electrode extension adds resistance in the welding circuit I increase in deposition rate, decrease in penetration and bead width

to keep a proper weld shape, when electrode extension is increased, voltage must also be increased when burn-through is a problem (e.g. thin gauge), increase electrode extension excessive electrode extension: it is more difficult to maintain the electrode tip in the correct position
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SAW operating variables

Depth of flux

depth of flux layer influence the appearance of weld

usually, depth of flux is 25-30 mm if flux layer is to deep the arc is too confined, result is a rough ropelike appearing weld if flux layer is to deep the gases cannot escape & the surface of molten weld metal becomes irregularly distorted if flux layer is too shallow, flashing and spattering will occur, give a poor appearance and porous weld
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SAW technological variables

Travel angle effect - Butt weld on plates

Penetration
Excess weld metal Tendency to undercut
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Deep
Maximum Severe

Moderate
Moderate Moderate

Shallow
Minimum Minimum

SAW technological variables

Earth position Direction of travel welding towards earth produces backward arc blow deep penetration +

convex weld profile

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SAW technological variables

Earth position Direction of travel welding away earth produces forward arc blow normal penetration depth +

smooth, even weld profile

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Weld backing
Backing strip

Backing weld

Copper backing

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Starting/finishing the weld

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SAW variants
Twin wire SAW welding two electrodes are feed into the same weld pool wire diameter usually 1,6 to 3,2 mm electrodes are connected to a single power source & a single arc is established normally operate with DCEP

offers increased deposition rate by up to 80% compared to single wire SAW

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SAW variants

Wires can be oriented for maximum or minimum penetration

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SAW variants
Tandem arc SAW process usually DCEP on lead and AC on trail to reduce arc blow requires two separate power sources

the electrodes are active in the same puddle BUT there are 2 separate arcs
increased deposition rate by up to 100% compared with single wire SAW
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SAW variants
SAW tandem arc with two wires

Courtesy of ESAB AB

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SAW variants

Single pool - highest deposition rate

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Twin pool - travel speed limited by undercut; very resistant to porosity and cracks

SAW variants
Tandem arc SAW process - multiple wires only for welding thick sections (>30 mm)

not suitable for use in narrow weld preparations (root passes)

one 4 mm wire at 600 A, 6.8 kg/hr
Courtesy of ESAB AB

tandem two 4 mm wires at 600 A, 13.6 kg/hr

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SAW variants
Strip cladding needs a
special welding head

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SAW variants
Narrow gap welding for welding thick materials less filler metal required requires special groove preparation and special welding head

requires special fluxes, otherwise problems with slag removal

defect removal is very difficult
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SAW variants
Hot wire welding the hot wire is connected to power source & much more efficient than cold wire (current is used entirely to heat the wire!)

increase deposition rates up to 100%

requires additional welding equipment, additional control of variables, considerable set-up time and closer operator attention
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SAW variants
SAW with metal powder addition
increased deposition rates up to 70%; increased welding speed gives smooth fusion, improved bead appearance, reduced penetration and dilution from parent metal & higher impact strength metal powders can modify chemical composition of final weld deposit does not increase risk of cracking

do not require additional arc energy

metal powder can be added ahead or directly into the weld pool

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SAW variants
SAW with metal powder addition magnetic attachment of powder

SAW with metal cored wires

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SAW variants
Storage tank SAW of circular welds

Courtesy of ESAB AB
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Advantages of SAW
high current density, high deposition rates (up to 10 times those for MMA), high productivity deep penetration allowing the use of small welding grooves fast travel speed, less distortion deslagging is easier uniform bead appearance with good surface finish and good fatigue properties can be easily performed mechanised, giving a higher duty cycle and low skill level required provide consistent quality when performed automatic or mechanised Virtually assured radiographically sound welds arc is not visible little smoke/fumes are developed
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Submerged Arc Welding

Advantages
Low weld-metal cost Easily automated Low levels of ozone High productivity No visible arc light Minimum cleaning

Disadvantages
Restricted welding positions Arc blow on DC current Shrinkage defects Difficult penetration control Limited joints

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