SAW (SUBMERGED ARC WELDING)

Kunal Parikh, SEPL,Vadodara

Contents
1. Process Description
2. Principle of Operation
3. Process Advantages
4. Process Limitations
5. Process Variables
6. Types of Electrodes & Flux (With Specifications of Standard)
7. Types of SAW Welding Processes
8. Welding Equipment for SAW
9. Welding Defects in SAW
10. SEPL’s Scope for FY 2020-21
1. Process Description
 Submerged arc welding (SAW) 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.
 In submerged arc welding, the arc is covered by a flux. This flux plays a main role in that (1)
the stability of the arc is dependent on the flux,(2) mechanical and chemical properties of
the final weld deposit can be controlled by flux, and (3) the quality of the weld may be
affected by the care and handling of the flux.
 Submerged arc welding is a versatile production welding process capable of making welds
with currents up to 2000 amperes, AC or DC using single or multiple wires or strips of filler
metal. Both AC and DC power sources may be used on the same weld at the same time.
 Applications included following segments where this can be opted.
 Pressure vessels like boilers
 Structural Outline,Pipes,Earth moving tools,Shipbuildings,railroad construction and
locomotives.
 Reparing of large machine spares/tools.
 Pre-Engineered buildings and sturctures
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2. Principle of Operation
 In submerged arc welding, the end of continuous bare wire electrode is inserted
into a mound of flux that covers the are or joint to be welded. An arc is initiated
and a wire-feeding mechanism then begins to feed the electrode wire towards the
joint at a controlled rate, and the feeder is moved manually or automatically along
the weld seam. For machine or automatic welding, the work may be moved
beneath a stationary wire feeder.
 Flux is continually fed in front of and around the electrode, and continuously
distributed over the joint.
 It is important that the slag is completely removed before making another weld
pass.
 Following are the factors which determines selection of SAW
 Chemical composition and mechanical properties required of the final deposit.
 Thickness of the base metal to be welded
 Joint accessibility
 Position in which the weld is to be made
 Frequency or volume of welding to be performed
3. Process Advantages
 3.1 It prevents hot materials from splattering and splashing onto workers
 3.2 It prevents high levels of radiation from being emitted into the air
 3.3 It does not require added pressure to weld because it is already generated by
the electrode
 3.4 It helps quickly welding together thin metal sheets and creates a secure fusion
between welds
 3.5 It produces high productivity, fast travel speed, high repeatability, and quality
results.
 3.6 Smooth, uniform finished weld with no spatter.
 3.7 Little or no smoke.
 3.8 No arc flash, thus minimal need for protective clothing.
 3.9 high utilization of electrode wire.
 3.10 Easy automation for high-operator factor.
4.Process Limitation
 4.1 Limitation of usage is restricted up to specific grades of steel, stainless steel
and nickel alloy.
 4.2 Application is also limited for the material which are long straight or rotated
pipes.
 4.3 Despite having safety advantages there is still the risk of having the residue
from the flux left behind which could be harmful to employee’s health.
 4.4 The application is imperfect to direct seams vessels, and pipes.
5. Process Variables
 The primary operating variables in SAW are
 5.1 Welding Amperage
 5.2 Welding Voltage
 5.3 Welding Speed/Travel Speed
 5.4 Electrode Size
 5.5 Electrode Extension
 5.6 Width and depth of the layer of flux
 5.7 Type of Electrode
 5.8 Type of flux and particle distribution
 6. Types of Electrodes and Fluxes
As we know SAW process constitutes two consumables. ELECTRODES & FLUX.
 ELECTRODES:- Submerged Arc Filler wire produce weld deposits matching carbon steel, low alloy steel, high
carbon steel, special low alloy steels, stainless steels, nickel alloys and special alloys for surfacing applications.
These filler wires are supplied as bare solid wire and as composite metal-cored electrodes. ( Similar to FCAW
Electrodes).
 These filler wires are normally packaged as coils or drums weight ranging from 12 kg to 450 kg. Large
electrode packages are economical for the customer as it increase operating efficiency and eliminate end of
coil wastages.
 Steel filler wires are usually copper coated, except those for welding corrosion resisting materials or for certain
nuclear applications. The copper coating provides good shelf life, decrease contact tube wear and improves
electrical conductivity. Electrodes are packaged to ensure long shelf life when stored indoors under normal
conditions.
 Submerged arc welding electrodes vary in size from 1.60mm to 6.00mm in diameter. The wide amperage
ranges are typical of submerged arc welding.
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 In classification of the various grades following are the denotes and their meaning.
 “ E” Stands for Solid Electrode
 “L” indicates that the solid electrode is comparatively low in Manganese content.
 “M” indicates that the solid electrode is having medium Manganese content.
 “H” indicates that the solid electrode is having higher Manganese content.
 The one or two digits following the Mn designator Indicate the nominal carbon content of the electrode.
 The Letter “K” which appears in some designations indicates that the electrode is made from a heat of silicon-killed
steel.
 This means solid electrode shall be identified only on the basis of their chemical composition.

For Example EM 12K

E= Indicates Solid Electrode( Wire)

M= Indicates that it contains medium Mn.
12= Indicates nominal Carbon Content
K= Indicates that this wire is being made up of silicon-killed steel.
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 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, and influence the shape of the
weld bead and its mechanical properties. Fluxes are granual mineral compounds mixed according to various
formulations. Based on the choice of several manufacturing methods, the different types of fluxes are
fused/bonded fluxes, agglomerated fluxes and Mechanically mixed.
(A) Classification Based on Design
 Fused Fluxes:- To manufacture a fused flux, the raw materials are dry mixed and melted in an electric furnace.
 Agglomerated Fluxes:- To manufacture agglomerated flux raw materials are powdered, dry mixed and bonded with either potassium
silicate, sodium silicate or a mixture of two.
 Mechanically Mixed Fluxes:- To produce a mechanically mixed flux, two or more fused or bonded fluxes are mixed in any ratio
necessary to yield the desired results.

 (B) Classification Based on Performance/Application/Standard

 Neutral Fluxes:-These are those which will not produce any significant change in the weld metal chemical analysis as a result of a
change in the arc voltage, and thus the arc length. The primary use of neutral fluxes is in multipass welding, especially when the base
metal exceeds 1 inch.(25.4mm)
 Active Fluxes:-Active fluxes are those which contains small amount of Mn, Si or both. These oxidizers are added to the flux to provide
improved resistance to porosity and weld cracking caused by contaminants on or in the base metal. The primary use for active fluxes is
to make single pass weld, especially on oxidized base metal.
 Alloy Fluxes:- Alloy fluxes are those which can be used with a carbon steel electrode to make alloy weld metal. The alloys for the
weld metal are added as ingredients in the flux. The primary use of such fluxes is to weld low alloy steel for hard facing.
 All fluxes having neutrality number N 35 or below are known as Neutral fluxes.
 Acid fluxes have a basicity index of 0.5 to 0.8; neutral fluxes 0.8 to 1.2; basic fluxes 1.2 to 2.5 and highly basic fluxes 2.5 to 4.0.
The basicity of a flux has a major effect on the weld metal properties, most importantly the notch toughness. As a general rule the
higher the basicity the higher the notch toughness.
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7. Types of Saw Welding Processes
 There are basically 3 types of saw welding processes are exists.

(1) SEMI-AUTOMATIC WELDING:- This type of welding is done with a hand-held welding gun, which delivers
both flux and the electrode. The electrode is driven by a wire feeder. Flux may be supplied by a gravity hopper
mounted on the gun or pressure fed through a hose. This method features manual guidance using relatively small
diameter electrodes and moderate travel speeds. The travel may by manual or driven by a small gun mounted
driving motor.

(2) AUTOMATIC WELDING:- It is done with equipment that performs the welding operation without
requiring a welding operator to continually monitor and adjust the controls. Expensive self-regulating equipment
can be justified in order to achieve high-production rates.

(3) MACHINE WELDING:- It employs equipment that performs the complete welding operation. However, it
must be monitored by a welding operator to position the work, start and stop welding, adjusting controls, and set
the speed of each weld.
8. Welding Equipment for Saw
9.Weld Defects in SAW

Following are the general defects observed in SAW

Welding application.

•Lack of fusion
•Lack of or incomplete penetration
•Cracks
•Porosity
•Inclusions
•Incorrect weld shape and size
•brittle fracture
•stress corrosion cracking
•fatigue failure
 10.SEPL’s Scope for FY2020-21
SAW WIRE
Product Family Product Types/Grades Form of Product
1.60mm (250 kg drum)
1.60mm (15 kg spool)
1.60mm (25 kg spool)
EM 12K 2.00mm (15 kg spool)
(FAB SAW) 2.00mm (25 kg spool)
2.40mm (25 kg spool)
3.20mm (25 kg spool)
4.00mm (25 kg spool)
Mild Steel
1.60mm (250 kg drum)
1.60mm (15 kg spool)
1.60mm (25 kg spool)
EL 8 2.00mm (15 kg spool)
(FAB SAW) 2.00mm (25 kg spool)
2.40mm (25 kg spool)
3.20mm (25 kg spool)
4.00mm (25 kg spool)
SAW FLUX
Product Family Product Types/Grades Form of Product
FABMELT 820 A
FABMELT 555 A
25 KG HDPE BAG WITH LINER SEALED
Mild Steel
INSIDE
FABMELT 710 XB
FABMELT 310 XB
AWS Classification Application/Segment
Structural Welding ,High speed fillet
welding,Fabrication of H & I
Beams,Fabriction of boilers
Engineering ,Railways, Pipe Industries and
Wind mill manufacturing,Heavy Engineering
AWS SFA/A 5.17 General Fabrication,PEB
General Fabrication, Boiler and Pressure
Vessel, Long & Cir Seam Welding of
pipes,Fabrication of Cylinders.
AWS Classification
Application/Segment
AWS SFA/A 5.17
Structural welding, high speed fillet
F7AZ/EM 12k welding,Fabrication of H & I
Beams,Fabrication of Boilers.
General Fabrication, Long Seam & Cir Seam
F7AZ/PZ-EL8 welding of pipes. Fabrication of cylinders &
vessels.
General Fabrication, Long Seam & Cir Seam
F7A4/P4-EH-14 welding of pipes. Fabrication of Boilers &
Pressure Vessels.
F7A2/P4-EM-12 K General Fabrication, Boiler and Pressure
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