Submerged Arc Welding (SAW)

Submerged
Arc
Welding
(SAW)
Submerged Arc Welding produces coalescence of
metals by heating them with an arc between a bare
metal electrode and the work. The arc and molten
metal are submerged in a blanket of granular fusible
flux on the work. Pressure is not used,and filler metal
is obtained from the electrode and sometimes from a
supplemental source such as welding rod or metal
granules.
Sub merged Arc Welding is a versatile production

welding process capable of making welds with current
up to 2000 A ,Ac or Dc, using single or multiple wires
or strips of filler metal. boss Ac and Dc power sources
may be used on the same weld at the same time.
SAW
Submerged Arc Welding can be applied in
three different modes:
1. Semiautomatic welding: -
- hand-held welding gun, which delivers both flux and the
electrode.
this method features manual guidance using relatively small
diameter electrodes and moderate travel speeds.
the travel may be manual or driven by a small gun-mounted
driving motor.
2. Automatic welding:
- done without welding operator.
it take high-production rates.
3. Machine welding:
- it must be monitored by a welding operator to position the
work, start and stop welding, adjust the controls, and set the
speed of each weld.
SAW
Equipment
Equipment
*Power Sources
-DC Constant Voltage :
Current Range :400A-1500A:
- Semiautomatic:300-600A with 1.2,2and
2.4mm diameter electrode.
-Automatic:300-1000A with 2.4 to 6.4 mm
dameter electrodes
- DC Constant Current:
Current Range up to 1500A

Electrodes
Submerged Arc Electrodes produce weld
deposits matching carbon steel, low alloy
steel, high carbon steels, special alloy
steels, stainless steels, nickel alloys, and
special alloys for surfacing applications.
Electrodes are normally packaged as coils
or drums ranging in weight from11to 454 kg.
Electrodes vary in size from 1.6 to 6.4 mm
in diameter.
Fluxes
Fluxes shield the molten weld pool from the
atmosphere by covering the metal with molten
slag. Fluxes clean the molten weld pool, modify
the chemical composition of the weld metal, play
main role in stability of the arc, and influence the
shape of the weld bead and its mechanical
properties.
Based on the choice of several manufacturing
methods, the different types of Fluxes are:
- Fused Fluxes.
- Bonded Fluxes.
- mechanically Mixed Fluxes.
* Fused fluxes:
Advantage:
1. Good chemical homogeneity.
2. Easy removal of the fines without affecting the flux
composition.
3. Not hygroscopic normally, which simplifies handling,
storage, and welding problems.
4. Reading recycled through feeding and recovery
systems without significant change in particle size or
composition.
Disadvantage:
1. Difficulty of adding deoxidizers and Ferro-alloys to
them during manufacture without segregation or
extremely high losses.
2. The high temperature needed to melt the raw
ingredients limit the range of flux compositions.
* Bonded fluxes:
Advantage:
1. Easy addition of deoxidizers and alloying
elements.
2. Usable with thicker layer of flux when welding.
3. Color identification.
Disadvantage:
1. Tendency for some fluxes to absorb moisture in
a manner similar to coatings on some
shielded metal arc electrodes.
2. Possible change in flux composition due to
segregation or removal of fine mesh particles.
* Mechanically mixed fluxes:
Advantage:
Several commercial fluxes may be mixed for
highly critical or proprietary welding operations.
Disadvantage:
1. Segregation of combined fluxes during
shipment, storage, and handling.
2. Segregation occurring in the feeding and
recovery systems during the welding operation.
3. Inconsistency in the combined flux from mix to
mix.
FXXX-EXX
X
SAW Filler Metal Identification
System
Flux
FXXX-EXX
X
System
Tensile Strength
FXXX-EXX
X
System
Heat Treatment
FXXX-EXX
X
System
Impact Test Temperature
FXXX-EXX
X
System
Electrode
FXXX-EXX
X
System
Electrode Classification
(Low, Medium, High - Mn%)
FXXX-EXX
X
System
Electrode Classification
(8 through 16 for chemistry)
F7A6-EM12K
SAW Filler Metal Example
General Process Applications
Pressure vessel fabrication.
Ship and barge building.
Railroad car fabrication.
Pipe manufacturing.
Fabrication of structural members where
long welds are required.
Operating Variables
Control of the operating variables in submerged
arc welding is essential if high production rates
and welds of good quality are to be obtained.
These variables are the following:
1. Welding amperage.
2. Type of flux and particle distribution.
3. Welding voltage.
4. Welding speed.
5. Electrode size.
6. Electrode extension.
7. Type of electrode.
8. Width and depth of layer of flux.
Weld Quality
Porosity problems
Submerged arc deposited weld metal is usually clean and free of
injurious porosity because of the excellent protection afforded by
the blanket of molten slag.
various factors that may cause porosity are the following:

1. Contamination in the joint.
2. Electrode contamination.
3. Insufficient flux coverage.
4. Entrapped flux at the bottom of the joint.
5. Contamination in the flux.
6. Segregation of constituents in the weld metal.
7. Excessive travel speed.
8. Slag residue from tack welds made with covered electrodes.
Cracking problems
These cracks occurs by:
- Stresses at the point where the weld metal is solidifying.
One solution to this problem is keep the depth of the
weld bead less than or equal to the width of the face of
the weld (fig).
- diffusible hydrogen in the weld metal (delayed cracking).
the hydrogen may enter the molten weld pool from the
following sources: flux, grease or dirt on the electrode or
base metal.
to avoid the hydrogen:
1.remove the mositure from the flux.
2.remove oil, grease, or dirt from the electrode and base
metal.
3.Incease the work temperature to allow more hydrogen
to escape during the welding operation.
Width vs Depth Ratio
Crack
SAW Advantages
High deposition rate
Deep penetration
Mechanized process
Hand-held process
Good for overlay of large areas
High operator appeal
SAW Limitations
Flat or horizontal fillets only
Extensive setup time
Needs positioning equipment
Arc not visible to operator
Slag removal
SAW Discontinuities
Groove alignment
Slag inclusions
Porosity
Incomplete fusion
Cracking (W/D ratio)

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What are the three modes of SAW?

What factors can cause porosity in SAW welds?

Submerged

Sub merged Arc Welding is a versatile production

various factors that may cause porosity are the following:

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