SUBMERGED ARC WELDING

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 Introduction

SAW

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 Principle of operation

• Uses heat generated by arc.

• Arc generate between electrode

and work piece.

• Welding arc and weld pool under

flux.

• Cover of molten flux to prevent

accessibility of atmospheric gas.
http://www.twi.co.uk
• Formation of slag.
SAW process

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 Component of SAW system

 Power Source:
• Both AC and DC
• AC- with large diameter electrode (<4mm)
• DC- with smaller diameter electrode (<2.5mm)

 Welding Electrode:
• Diameter of electrode range (1-5 mm)
• Wire of steel with copper coat

Saw Flux: Types of flux :

Role – protection of weld • Fused fluxes: uniform chemical composition, easy
pool from gases recycling
• Bonded fluxes: Easy to add deoxidizers, allow thick layer
• Agglomerated fluxes:
• Mechanically mixed fluxes: several flux easily mix &
made for critical application

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 Welding Parameter

Welding Current:

• Most influence parameter

• Determine melting rate of electrode, penetration depth and

weld bead geometry

• High current- lead to burn
• Low current- cause lack of penetration and fusion
• Welding current determined by thickness of plate and electrode
diameter

Effect of electrode diameter for same current

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Welding Voltage :

•It affect on melting rate of electrode

•Range from 20-35v
•High voltage- flatter & wide weld bead and more flux consumption
•Low voltage – narrow weld bead and poor slag

Welding Speed :
•Higher speed- reduce heat input, low deposition rate, shallow
penetration and porosity
•Slow speed- increased tendency of melt and reduce development
of porosity and slag inclusion.

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 Advantages :  Limitations :
• High productivity due to high • Invisibility of welding arc
deposition rate • Difficult to maintaining mound of
• High depth of penetration allow for flux cover
weld thick section • Increased tendency of weld for thin
• Smooth weld bead with less stress sheet

Applications:

•Welding of steels in sectors like : •Cladding carbon and alloy steels with stainless
Shipbuilding steel and nickel alloy deposits.
Offshore
Structural industries •Surfacing of worn out parts for different
pressure vessel industries purposes such as reclamation, hard facing and
fabrication of pipes cladding
Penstocks
LPG cylinders
bridge girders.
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 Case Study - I
Combined effect of flux and welding parameters on chemical composition and mechanical
properties of submerged arc weld metal
P. Kanjilal , T.K. Pal , S.K. Majumdar
OBJECTIVE :To study the combined effect of flux and welding parameters on the weld
metal chemistry and mechanical properties using statistical design of experiment.
EXPERIMENT : Material-

Rotatable design model in statistical experiments mixture -

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Source : Journal of Materials Processing Technology 171 (2006) 223–231
Cont…

RESULTS :
1. Among the welding parameters, polarity has a profound influence on weld
metal chemical composition.
2. Welding speed influences weld metal carbon content through oxidation
reaction; whereas weld metal sulphur and phosphorous content are affected by
dilution of weld deposit.
3. Welding current influences weld metal manganese content through slag–metal
reaction.
4. Transfer of nickel from flux to weld, is found to be impeded by oxides formed
during slag–metal reaction.
5. Weld metal yield strength and hardness are mainly determined by welding
parameters; whereas the impact toughness is determined by flux mixtures
variables.

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 Case Study - II
Analysing the Effect of Parameters in Multipass Submerged arc Welding Process
Deepti Jaiswal

OBJECTIVE : To investigate and correlate the relationship between various parameter and
micro hardness.
EXPERIMENT : Material –SA-516 Grade 70 (boiler plate)
Electrode wire - AWS SFA 5.17, EL-08
Flux- AWS 5.17 OK FLUX 10.71 L

RESULTS :

1 Effect of current on micro hardness

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Source : ISSN : 2319 – 3182, Volume-2, Issue-2, 2013
Cont…

2 Effect of voltage on microhardness

3 Effect of welding speed on microhardness

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 Case Study - III
Recycling of slag to act as a flux in submerged arc welding
Kulwant Singha, Sunil Pandeyb

OBJECTIVE : To develop recycling technology that allows the use of slag as a fresh flux.

METHODOLOGY :
Processing of slag : Weld Qualification Test:
1. Collection of slag. 1 Arc stability
2. Crushing and sieving of slag. 2 Slag detachability and visual
3. Welding with crushed pure slag. inspection
4. Welding with fresh flux. 3 Dye penetration test
5. Comparison of weld metal composition. 4 Radiography
6. Modification in slag. 5 Tensile and impact testing
7. Welding with modified (recycled) slag.
8. Chemical composition of weld metal
deposited with recycled slag.
9. Repeat step number 6, 7 and 8 till
required composition of weld
metal is achieved.
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Source : Resources, Conservation and Recycling 53 (2009) 552–558
Cont…

RESULTS :
1. Submerged arc welding slag can be recycled after necessary modification.
2. Weld metal chemistry achieved with recycled slag was within the acceptable range
of ASME SFA 5.17-89 specifications.
3. Recycled slag can produce acceptable weld bead geometry.
4. Penetration and bead width increased with an increase in welding wire feed rate
and decreased with increase in travel speed.
5. The mechanical properties of weld metal deposited with recycled slag were
acceptable as per ASME SFA 5.17-89.
6. Good appearance of beads without any visual defects was observed.
7. Arc stability and slag detachability both were good with the recycled slag.

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 REFERNCES

[1] Welding Technology for engineers – Baldev raj, V Shankar, A.K.Bhaduri: Narosa Publication.
[2] Welding Technology and Design- V.M. Radhakrishnan (second edition).
[3] P. Kanjilal, T.K. Pal and S.K. Majumdar, Combined effect of flux and welding parameters on chemical
composition and mechanical properties of submerged arc weld metal. Journal of Materials
Processing Technology, Vol.171: 223-231 (2006).
[4] Deepti Jaiswal, Analysing the effect of parameters in multi pass submerged arc welding process,
ISSN vol.2 :2319-2325 (2013).
[5] Kulwant Singh, Sunil pandey , Recycling of slag to act as a flux in submerged arc welding, Resources ,
Conservation and Recycling, vol.53:552-558 (2009).
[6] S.shen, I.N.A. Oguocha ,The effect of heat input on weld bead geometry of submerged arc welded
ASTM A709 Grade 50 steel joint, journal of material processing technology, vol. 212: 286-
294( 2012).
[7] Jerzy Nowacki, Pawel Rybicki, The influence of welding heat input on submerged arc welded duplex
steel joints imperfection, journal of material processing technology ,vol.164: 1082-1088( 2005).
[8] Prasanta Kanjilal; Tapan Kumar Pal ;Sujit Kumar Majumdar,Prediction of Mechanical Properties in
Submerged Arc Weld Metal of C-Mn Steel,Journal of materials and manufacturing process, Vol. 22:
114-127(2007).

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THANK YOU…!

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