4.

Submerged Arc Welding (SAW)

 Submerged Arc Welding (SAW)
Principle.

Electricity is passed through an electrode which

jumps between the electrode and the work piece.

The arc produces great heat melting the

electrode and the work piece causing the edges

to fuse together.

The electrode is a wire fed consumable.

Submerged Arc Welding (SAW)
 Submerged Arc Welding (SAW)
Operation.

The arc melts the two edges to be joined as well as

the electrode forming the weld pool.
The arc is submerged by a granulated flux released
from a hopper ahead of it. This flux melts with the
heat of the arc protecting the weld pool and forming
a slag that controls cooling.
Exam answer Diagram , draw and label, note the direction
 Submerged Arc Welding (SAW)
Uses.
This is an ideal automated welding
process. It is ideal for long runs. It is used
for producing steel girders or beams used
in construction.
5.Electro-Slag Welding.
Electro-Slag Welding.
Principle.
Electricity is passed between two couples
on either side of the plates. This causes
the materials in the gap to melt as well as
the edges of the plates. This form the weld
pool.
Electro-Slag Welding.

Draw,
exam answer
Operation.

1.Two pieces of metal are placed between the

electrodes.

2.The electrodes are then closed on the piece causing

the circuit to complete.

3.The resistance in the metal between the electrodes

causing them to melt and fuse together.
Uses.

This is generally used to join very thick plates

together giving a series of overlapping welds
until the two plates are fully joined.
It is suitable for automatic welding as it is
used on large plates usually.
6. Resistance Welding
Resistance Welding.(Spot Welding)
Principle.
Electricity is passed between two electrodes with the
pieces to be joined in between. As the electricity passes
through the material the resistance of the metals cause
the metals to melt fusing them together.
Operation.
1. Two pieces of metal are placed between the electrodes.
2. The electrodes are then closed on the piece causing
the circuit to complete.
3. The resistance in the metal between the electrodes
causing them to melt and fuse together.
Uses.
. used to join light gauge steel sheet metal. Car
Production
Resistance Welding. (Spot Welding)
Draw circle,
exam answer
 el d i n g .
S e am W
i s tan ce
Res
 Resistance Seam Welding.
Principle
This is exactly the same as spot welding except that a
continuous is produced.
Operation.
1. The first method is similar to spot welding. Here however the
spots are overlapped to form a continuous seam. This is called
Stitch welding.
2. The second method is to replace the electrodes with rollers
that cause a continuous seam to be produces.
Uses.
. This is also used to weld sheet metal except that a continuous
seam is required perhaps the production of a water proof tank.
Draw, exam answer
7.Gas welding
 Gas welding
Metals are fused together and the gap is filled with a filler rod
Oxygen and acetylene are mixed together to generate a
flame to melt the weld joint.
Oxygen is pressurised into the cylinder.

Acetylene is dissolved in a porous material called acetone,

which will absorb 25 times its own volume of Acetylene.
Acetylene would explode if it were stored under pressure.
Application; Car Body Repairs
Draw this
diagram
and take note of
Colours of
Hoses and
Cylinders
Welding Regulators
 Oxy-acetylene flames

Draw these, exam answer

 Neutral Flame

1 part oxygen /1 part acetylene, used to weld most

steels and irons. 3350*
 Oxidising Flame
Is due to excess oxygen, 1.5 parts oxygen /1
part acetylene, used to weld copper, brass
and bronzes.(3500C)
Carburising Flame
Is due to excess acetylene 1 part acetylene /
0.9 part oxygen, used to weld alloy steels
and aluminium.(3150C)
 Safety while gas welding
Gas cylinders are colour-coded with acetylene having a maroon
cylinder and oxygen having a black cylinder
Regulators cannot be interchanged with colour coding

Acetylene has left handed thread fittings

Flashback arrestors are placed on gas lines

Hoses are colour-coded

Regulators are fitted to cylinders with an over-ride valve

Adequate ventilation systems.
 Multi-runs.
Advantages of multi-run welds:

A series of welds are run across the metals to be joined in

multi-run welding.
A superior weld is produced as each weld has a post heating
effect on the previous run.
The finished weld is stronger and more refined in structure than
single run welds.
Shielded arc.
This is the protection of the weld pool by an inert gas
preventing oxidation of the weld.
Edge preparation.
This is the preparation of the edges to be welded.
They should be free of rust and oil to allow for a
quality weld and should be tapered slightly to allow
for a good joint.
Slag inclusion.
This is a fault where the slag drops into the weld
pool and becomes part of it weakening the weld.
This is caused by moving the welding apparatus to
slowly. Welding at the correct pace will prevent this.
Porosity.
Porosity is the presence of air bubbles in the weld. This is
caused by moving the welding apparatus to quickly not
giving the weld pool a chance to form properly. This is
controlled by welding at the correct pace.

Lack of penetration.
This is again a problem with the weld pool. Due to a lack
of temperature the edges to be joined do not melt to form
the weld pool and fuse together. This can be prevented
by setting the welder to the correct power setting.