Mechanical faculty Zenica

University Zenica
Public lecture
Theme: Submerged arc welding
Student: Profesor:
Alma Jusufovi !"#$%" dr&sci& Aida Tarabar' lector
(ontent:
)& Uvod &&&&&&&&&&&
*& Submerged arc welding &&&&&&&&
*&)& +eatures &&&&&&&
*&*& Material a,,lications &&&&&&&&&&&&&
*&-& Advantages &&&&&&
*&.& /imitation &&&&&&&&&&
*&& 0ire &&&&
*&1& +lu2 &&&&&&
*&#& A,,lications &&&&&&&&&
-& Za3l4u5a3 &&&&&&&
.& /iteratura &&&&&&&&&&&&
*
)& Uvod:
0elding is a fabrication ,rocess that 4oins materials usually metals or thermo,lastics'
by causing coalescence& This is often done by melting the wor3,ieces and adding a filler
material to form a ,ool of molten material 6the weld ,ool7 that cools to become a strong 4oint'
with ,ressure sometimes used in con4unction with heat' or by itself' to ,roduce the weld& This
is in contrast with soldering and bra8ing' which involve melting a lower9melting9,oint material
between the wor3,ieces to form a bond between them' without melting the wor3 ,ieces&
There are several different ways to weld' such as: Shielded Metal Arc 0elding' :as Tungsten
Arc 0elding' Tungsten ;nert :as and Metallic ;nert :as& M;: or Metallic ;nert :as involves
a wire fed <gun< that feeds wire at an ad4ustable s,eed and s,rays a shielding gas 6generally
,ure Argon or a mi2 of Argon and (=*7 over the weld ,uddle to ,rotect it from the outside
world& T;: or Tungsten ;nert :as involves a much smaller hand9held gun that has a tungsten
rod inside of it& 0ith most' you use a ,edal to ad4ust your amount of heat and hold a filler
metal with your other hand and slowly feed it& Stic3 welding or Shielded Metal Arc 0elding
has an electrode that has flu2' the ,rotectant for the ,uddle' around it& The electrode holder
holds the electrode as it slowly melts away& Slag ,rotects the weld ,uddle from the outside
world& +lu29(ore is almost identical to stic3 welding e2ce,t once again you have a wire
feeding gun' the wire has a thin flu2 coating around it that ,rotects the weld ,uddle&
Many different energy sources can be used for welding' including a gas flame' an electric arc'
a laser' an electron beam' friction' andultrasound& 0hile often an industrial ,rocess' welding
may be ,erformed in many different environments' including o,en air' under waterand
in outer s,ace& 0elding is a ,otentially ha8ardous underta3ing and ,recautions are re>uired to
avoid burns' electric shoc3' vision damage' inhalation of ,oisonous gases and fumes' and
e2,osure to intense ultraviolet radiation&
Until the end of the )"th century' the only welding ,rocess was forge welding'
which blac3smiths had used for centuries to 4oin iron and steel by heating and
hammering& Arc welding and o2yfuel welding were among the first ,rocesses to develo, late
in the century' and electric resistance welding followed soon after& 0elding technology
advanced >uic3ly during the early *%th century as 0orld 0ar ; and 0orld 0ar ;; drove the
demand for reliable and ine2,ensive 4oining methods& +ollowing the wars' several modern
welding techni>ues were develo,ed' including manual methods li3e shielded metal arc
welding' now one of the most ,o,ular welding methods' as well as semi9automatic and
automatic ,rocesses such as gas metal arc welding' submerged arc welding' flu29cored arc
welding and electroslag welding& ?evelo,ments continued with the invention of laser beam
welding' electron beam welding' electromagnetic ,ulse welding and friction stir welding in
the latter half of the century& Today' the science continues to advance& @obot welding is
-
common,lace in industrial settings' and researchers continue to develo, new welding
methods and gain greater understanding of weld >uality&
*& Submerged arc welding:
In SAW (Submerged Arc Welding) an arc is struck between the work piece and
the end of a consumable electrode, both of which are covered by a layer of granular flux
(hence submerged! arc)" #he arc is therefore hidden" Some of the flux melts to provide a
protective slag cover over the weld pool" #he remainder is collected for re$use"
Submerged arc welding 6SA07 is a common arc welding ,rocess& The first ,atent on the
submerged9arc welding ,rocess was ta3en out in )"- and covered an electric arc beneath a
bed of granulated flu2& =riginally develo,ed by the /inde 9 Union (arbide (om,any& ;t
re>uires a non9continuously fed consumable solid or tubular 6flu2 cored7 electrode& The
molten weld and the arc 8one are ,rotected from atmos,heric contamination by being
<submerged< under a blan3et of granular fusible flu2 consisting of lime' silica' manganese
o2ide' calcium fluoride' and other com,ounds& 0hen molten' the flu2 becomes conductive'
and ,rovides a current ,ath between the electrode and the wor3& This thic3 layer of flu2
com,letely covers the molten metal thus ,reventing s,atter and s,ar3s as well as su,,ressing
the intense ultraviolet radiation and fumes that are a ,art of the shielded metal arc
welding 6SMA07 ,rocess&
Submerged arc welding 6SA07 is so named because the weld and arc 8one are submerged
beneath a blan3et of flu2& The flu2 material becomes conductive when it is molten' creating a
,ath for the current to ,ass between the electrode and the wor3,iece& The flu2 blan3et
,revents s,atter and s,ar3s' while shielding ultraviolet light and fumes that are normally a
,art of shielded metal arc welding& The flu2 usually is su,,lied to the welding head via a
small ho,,er& A collection system gathers the e2cess flu2 for reuse&
SA0 is normally o,erated in the automatic or mechani8ed mode' however' semi9automatic
6hand9held7 SA0 guns with ,ressuri8ed or gravity flu2 feed delivery are available& The
,rocess is normally limited to the flat or hori8ontal9fillet welding ,ositions 6although
hori8ontal groove ,osition welds have been done with a s,ecial arrangement to su,,ort the
flu27& ?e,osition rates a,,roaching )%% lb$h 6. 3g$h7 have been re,orted A this com,ares to
B)% lb$h 6 3g$h7 6ma27 for shielded metal arc welding& Although (urrents ranging from -%%
to *%%% A are commonly utili8ed'
C)D
currents of u, to %%% A have also been used 6multi,le
arcs7&
Single or multi,le 6* to 7 electrode wire variations of the ,rocess e2ist& SA0 stri,9cladding
utili8es a flat stri, electrode 6e&g& 1% mm wide 2 %& mm thic37& ?( or A( ,ower can be used'
and combinations of ?( and A( are common on multi,le electrode systems& (onstant
voltagewelding ,ower su,,lies are most commonly usedE however' constant current systems
in combination with a voltage sensing wire9feeder are available&
.
%igure &' Submerged arc welding machine a)

%igure (' Submerged arc welding machine b)

*&)& +eatures:
0elding head: ;t feeds flu2 and filler metal to the welding 4oint& Flectrode 6filler metal7 gets
energi8ed here&
+lu2 ho,,er: ;t stores the flu2 and controls the rate of flu2 de,osition on the welding 4oint&
+lu2: The granulated flu2 shields and thus ,rotects molten weld from atmos,heric
contamination& The flu2 cleans weld metal and can modify its chemical com,osition also& The
flu2 is granulated to a definite si8e& ;t may be of fused' bonded or mechanically mi2ed ty,e&
The flu2 may consist of fluorides of calcium and o2ides of calcium' magnesium' silicon'
aluminium and manganese& Alloying elements may be added as ,er re>uirements& Substances
evolving large amount of gases during welding are never mi2ed with the flu2& +lu2 with fine
and coarse ,article si8es are recommended for welding heavier and smaller thic3ness
res,ectively&
Flectrode:SA0 filler material usually is a standard wire as well as other s,ecial forms& This
wire normally has a thic3ness of )$)1 in& to )$. in& 6)&1 mm to 1 mm7& ;n certain
circumstances' twisted wire can be used to give the arc an oscillating movement& This hel,s
fuse the toe of the weld to the base metal&
C*D
The electrode com,osition de,ends u,on the
material being welded&Alloying elements may be added in the electrodes& Flectrodes are
available to weld mild steels' high carbon steels' low and s,ecial alloy steels' stainless steel
and some of the nonferrous of co,,er and nic3el& Flectrodes are generally co,,er coated to
,revent rusting and to increase their electrical conductivity& Flectrodes are available in
straight lengths and coils& Their diameters may be )&1' *&%' *&.' -' .&%' .&!' and 1&. mm& The
a,,ro2imate value of currents to weld with )&1' -&* and 1&. mm diameter electrodes are )%G
-%' *%G!%% and 1%G)-% Am,s res,ectively&
Welding )peration'
The flu2 starts de,ositing on the 4oint to be welded& Since the flu2 when cold is non9conductor
of electricity' the arc may be struc3 either by touching the electrode with the 4ob or by ,lacing
steel wool between electrode and 4ob before switching on the welding current or by using a
high fre>uency unit& ;n all cases the arc is struc3 under a cover of flu2& +lu2 otherwise is
insulator but once it melts due to heat of the arc' it becomes highly conductive and hence the
current flow is maintained between the electrode and the 4ob through the molten flu2& The
u,,er ,ortion of the flu2' in contact with atmos,here' which is visible remains solid granular
i&e&' unchanged and can be reused& The lower' melted flu2 becomes slag' which is waste
material and must be removed after welding&
1
Submerged Arc ti,s
The electrode at a ,redetermined s,eed is continuously fed to the 4oint to be welded& ;n semi9
automatic welding sets the welding head is moved manually along the 4oint where as
#
automatic welding a se,arate drive moves either the welding head over the stationary 4ob or
the 4ob moves$rotates under the stationary welding head&
The arc length is 3e,t constant by using the ,rinci,le of a self9ad4usting arc i&e&' if due to
certain reasons arc length decreases' arc voltage will increase' arc current and therefore burn9
off rate will increase thereby causing the arc to lengthen& The reverse occurs if the arc length
increases than the normal&
Hac3ing ,late of steel or co,,er may be used to control ,enetration and to su,,ort large
amounts of molten metal associated with the ,rocess&
Iey SA0 ,rocess variablesCeditD
0ire feed s,eed 6main factor in welding current control7
Arc voltage
Travel s,eed
Flectrode stic39out 6FS=7 or contact ti, to wor3 6(TT07
Polarity and current ty,e 6A( or ?(7 and variable balance A( current
!
*&*& Material a,,lications:
(arbon steels 6structural and vessel construction7
/ow alloy steels
Stainless steels
Jic3el9based alloys
Surfacing a,,lications 6wear9facing' build9u,' and corrosion resistant overlay of
steels7
"
("*" Advantages'
Kigh de,osition rates 6over )%% lb$h 6. 3g$h7 have been re,orted7&
Kigh o,erating factors in mechani8ed a,,lications&
?ee, weld ,enetration&
Sound welds are readily made 6with good ,rocess design and control7&
Kigh s,eed welding of thin sheet steels u, to m$min 6)1 ft$min7 is ,ossible&
Minimal welding fume or arc light is emitted&
Practically no edge ,re,aration is necessary&
The ,rocess is suitable for both indoor and outdoor wor3s&
/ow distortion
0elds ,roduced are sound' uniform' ductile' corrosion resistant and have good im,act
value&
Single ,ass welds can be made in thic3 ,lates with normal e>ui,ment&
The arc is always covered under a blan3et of flu2' thus there is no chance of s,atter of
weld&
%L to "%L of the flu2 is recoverable&
C
("+" ,imitations'
/imited to ferrous 6steel or stainless steels7 and some nic3el9based alloys&
Jormally limited to the )+' ):' and *+ ,ositions&
Jormally limited to long straight seams or rotated ,i,es or vessels&
@e>uires relatively troublesome flu2 handling systems&
+lu2 and slag residue can ,resent a health and safety concern&
@e>uires inter9,ass and ,ost weld slag removal&
SA0 is not suitable for every a,,lication& Since it is a flat or hori8ontal ,rocess' there are
limits to the ty,e of o,erations it can benefit& Also' it is mostly s,ecific to ferrous metals& =n
some materials such as aluminum' ,roblems with caustic flu2 negate the environmental and
safety advantages of SA0 and re>uire a different ,rocess&
)%
SA0 is 3nown for its ability to de,osit large amounts of metal >uic3ly' consistently' and
safely& The basic SA0 e>ui,ment is a ,ower source' control unit' wire unit' and no88le&
*&& 0ire:
SA0 is normally o,erated with a single wire on either A( or ?( current& (ommon variants
are:
twin wire
multi,le wire 6tandem or tri,le7
single wire with hot or cold wire addition
metal ,owder addition
tubular wire
submerged arc welding wire
*&1& +lu2:
+lu2es used in SA0 are granular fusible minerals containing o2ides of manganese'
silicon' titanium' aluminium' calcium' 8irconium' magnesium and other com,ounds such as
calcium fluoride& The flu2 is s,ecially formulated to be com,atible with a given electrode
wire ty,e so that the combination of flu2 and wire yields desired mechanical ,ro,erties& All
flu2es react with the weld ,ool to ,roduce the weld metal chemical com,osition and
mechanical ,ro,erties& ;t is common ,ractice to refer to flu2es as MactiveM if they add
manganese and silicon to the weld' the amount of manganese and silicon added is influenced
by the arc voltage and the welding current level& The the main ty,es of flu2 for SA0 are:
Honded flu2es 9 ,roduced by drying the ingredients' then bonding them with a low
melting ,oint com,ound such as a sodium silicate& Most bonded flu2es contain metallic
deo2idisers which hel, to ,revent weld,orosity& These flu2es are effective over rust and
mill scale&
+used flu2es 9 ,roduced by mi2ing the ingredients' then melting them in an electric
furnace to form a chemically homogeneous ,roduct' cooled and ground to the re>uired
))
,article si8e& Smooth stable arcs' with welding currents u, to *%%%A and consistent weld
metal ,ro,erties' are the main attraction of these flu2es&
submerged arc welding flu2
*&#& A,,lications:
SA0 is ideally suited for longitudinal and circumferential butt and fillet welds&
Kowever' because of high fluidity of the weld ,ool' molten slag and loose flu2 layer' welding
is generally carried out on butt 4oints in the flat ,osition and fillet 4oints in both the flat and
hori8ontal9vertical ,ositions& +or circumferential 4oints' the wor3,iece is rotated under a fi2ed
welding head with welding ta3ing ,lace in the flat ,osition& ?e,ending on material thic3ness'
either single9,ass' two9,ass or multi,ass weld ,rocedures can be carried out& There is virtually
no restriction on the material thic3ness' ,rovided a suitable 4oint ,re,aration is ado,ted& Most
commonly welded materials are carbon9manganese steels' low alloy steels and stainless steels'
although the ,rocess is ca,able of welding some non9ferrous materials with 4udicious choice
of electrode filler wire and flu2 combinations&
)*
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/iteratura:
htt,:$$www&twi9global&com$technical93nowledge$4ob93nowledge$submerged9arc9welding9
,rocess9%%$
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