PRESENTATION

BY
 TOPIC

SUBMERGED ARC
WELDING (SAW)
PROCESS
SAW PROCESS
 SAW PROCESS –
A BRIEF DESCRIPTION

Characteristics MMAW FCAW SAW

Size, mm 4.0 1.2 4.0

Welding speed, mm/min 140 200 500

Deposition efficiency, % 65 85 100

Effective arcing time, % 35 43 45

Arcing time/8 hr shift, hr 2.8 3.44 3.6

Deposition rate, kg/hr 1.48 3.42 7.0

Deposition/shift, kg 4.14 11.76 25.2

 SAW PROCESS –
COMMON GRADE OF WIRES

C Mn Si S P
Low Manganese wire
EL-8 0.10 0.25- 0.07 0.030 0.030
0.60
Medium Manganese wire
EM-12K 0.05- 0.80- 0.10- 0.030 0.030
0.15 1.25 0.35
High Manganese wire
EH-10K 0.07- 1.30- 0.05- 0.025 0.025
0.15 1.70 0.25
EH-14 0.10- 1.70- 0.10 0.030 0.030
0.20 2.20
 SAW LOW ALLOY STEEL
ELECTRODES AND FLUX

Grade C Mn Si S P Cr Ni Mo Cu Others
0.05- 0.95- 0.45-
0.2 0.025 0.025 - - 0.35 -
EA2 0.17 1.35 0.65
0.05- 1.20- 0.45-
0.2 0.025 0.025 - - 0.35 -
EA4 0.15 1.70 0.65
0.07- 0.45- 0.05- 1.00- 0.45-
0.025 0.025 - 0.35 -
EB2 0.15 1.00 0.30 1.75 0.65
0.05- 0.40- 0.05- 2.25- 0.90-
0.025 0.025 - 0.35 -
EB3 0.15 0.80 0.30 3.00 1.10
0.35- 0.05- 4.50- 0.45-
0.1 0.025 0.025 - 0.35 -
EB6 0.70 0.50 6.50 0.70
0.10- 1.50- 0.70- 0.40-
0.3 0.025 0.025 - 0.35 -
EF3 0.18 2.40 1.10 0.65
V: 0.03 Ti: 0.10
1.40- 0.20- 2.00- 0.30-
EM4 0.1 0.015 0.01 0.6 0.25 Zr: 0.10
1.80 0.60 2.80 0.65
Al: 0.10
0.75- 0.05- 2.10-
0.12 0.02 0.02 - - 0.35 --
ENi2 1.25 0.30 2.90
0.60- 0.05- 3.10-
0.13 0.02 0.02 0.15 - 0.35 -
ENi3 1.20 0.30 3.80
 SAW STAINLESS STEEL
ELECTRODES AND FLUX

WIRE
ER308L
ER309L
ER309LMo
ER316L
ER317L
FLUX
SS4
SS4(LT): For CVN Impact at minus 196oC.
 DIFFERENT TYPE OF WAGON
FABRICATED
SL. TYPE OF PURPOSE BASE MATERIAL WELDING CONSUMABLE
NO. WAGON
1 BTPN Transportation of finished IS 20 62 E-250 W1 Autotherme-Gr A
Petroleum Products like F1 SAF2
Petrol, Diesel, Kerosene,
Black Oil.
2 BTPGLN Transportation of LPG SA 516-Gr.70 W2 Autotherme-Gr B
F2 SAF4(SPL)
3 BOXNHL Transportation of Coal; IRSM44-SS Ferrite ER-308 L, E-308L-16
SS Cr10-12, Ni-1.5
4 BTAP Transportation of Alumina IS2062 Fe 410 (E250 Class-IV FCW 81W
A Cu) Electrode Class-D
5 BLCAM Transportation of Container IS 2062 Gr.E-450 C Electrode-C1 class, (E-9018 – D1)
Solid wire Class-III (ER-90SD2)
6 BOBYRN For Transportation of IS 2062 FCW, Class-IV electrode (E-81 T1
Railway use stone cheep; E-250Cu W) - Class-D.
Ballast.
7 BRN Transportation of Railway IS 2062 FCW, Class-IV electrode (E-81 T1
Slipper E-250Cu W) - Class-D
8 MGR (NTPC) Transportation of Coal for E-450 Electrode-C1 class, (E-9018 – D1)
NTPC personal use. Solid wire Class-III (ER-90SD2)
9 BCNHL Covered Wagon, for IS 2062 Gr.E-450 C Electrode-C1 class, (E-9018 – D1)
Transportation of Cement, Solid wire Class-III (ER-90SD2)
Fertilizer
WAGON FABRICATORS
 SAW PROCESS –
CLASSIFICATION OF FLUX

SAW Flux

Basicity Index Types

Fused Agglomerated
 SAW PROCESS –
FLUX DESCRIPTION

Fused fluxes are dark brown or black in colour with a

glasslike surface and angular in shape. They are general
purpose fluxes that require no preheating.

Agglomerated fluxes are light, roughly spherical in shape

and result better alloy recovery.

Agglomerated fluxes absorb moisture. So shall be re-dried

before use.

Particle size is important – finer flux for higher travel speed &
coarser flux for moderate travel speed is recommended.
 SAW PROCESS –
FLUX CLASSIFICATION

Welding flux Basicity Melting temp, C

<0.90 1100 – 1300
Acidic
Neutral 0.90 – 1.20 1300 – 1500
1.20 – 2.00
Basic >1500
High basic
>2.0 >1500

[CaO+CaF2+MgO+K2O+Li2O+BaO+SrO+0.5(MnO+FeO)]
Basicity =
[SiO2+0.5(Al2O3+TiO2+ZrO2)]
 SAW PROCESS –
AWS CLASSIFICATION

Carbon steel electrode & Fluxes (A5.17)

F X X X - E X X X- HX
(a) (b) (c) (d) (e) (f) (g)

(a) Indicates a SAW flux.

(b) Indicates the minimum tensile strength of the weld metal in

increments of 10 ksi.

(c) Designates the condition of heat treatment at which the tests

are to be conducted. ‘A’ for as-welded condition and ‘P’ for
post-weld heat-treated condition.
(d) Indicates the sub-zero temperature (F) at which the impact
strength of the weld metal referred to meets or exceeds 20 ft-
lb (27 J). For ‘Z’ impact is not defined.
 SAW PROCESS –
AWS CLASSIFICATION

Carbon steel electrode & Fluxes (A5.17)

F X X X - E X X X- HX
(a) (b) (c) (d) (e) (f) (g)

(e) The letter ‘E’ indicates a solid electrode and ‘EC’ indicates
a composite electrode.
(f) Classification of the electrode used in producing the weld
metal.
 SAW SFA 5.23 SPECIFICATON
OF LAS WIRE & FLUX

F X X X - E X X X- HX
(a) (b) (c) (d) (e) (f) (g)

(a) Indicates a SAW flux.

(b) Indicates the minimum tensile strength of the weld metal in

increments of 10 ksi.

(c) Designates the condition of heat treatment at which the tests

are to be conducted. ‘A’ for as-welded condition and ‘P’ for
post-weld heat-treated condition.
(d) Indicates the sub-zero temperature (F) at which the impact
strength of the weld metal referred to meets or exceeds 20 ft-
lb (27 J).
 SAW SFA 5.23 SPECIFICATON
OF LAS WIRE & FLUX

F X X X - E X X X- HX
(a) (b) (c) (d) (e) (f) (g)

(e) The letter ‘E’ indicates a solid electrode and ‘EC’ indicates
a composite electrode.
(f) Classification of the electrode used in producing the weld
metal.

(g) Optional supplemental diffusible hydrogen designator.

 SAW PROCESS - DILUTION

Weld metal A
B

Base metal Fusion line

Heat affected zone

Partially melted zone

Schematic sketch of a weldment

Dilution, % = B X 100/ (A+B)

 SAW PROCESS - DILUTION

Process Dilution, %

Oxyacetylene gas welding <5

Manual metal arc welding 10 – 30

Flux-cored arc welding 10 – 30

Submerged arc welding 10 – 40

 SAW PROCESS –
EFFECT OF VOLTAGE

Wider area acts as

more anchor point

High Voltage Low Voltage

 SAW PROCESS –
EFFECT OF VOLTAGE

Arc voltage affects dilution rather than penetration.

Bead width and dilution increase as the arc voltage

increases, but depth of penetration remains the same.

If the joint preparation is open, for example in a butt joint with

an angled 'V' preparation, increasing the arc voltage can
decrease the penetration.
 SAW PROCESS –
EFFECT OF POLARITY

DCEP gives the deepest penetration (electrode positive,

DCEP) since the maximum heat is developed at the tip of the
electrode instead of at the surface of the plate.

DCEP also gives the best surface appearance, bead shape

and resistance to porosity.

DCEN polarity is generally used for surfacing applications.

In Tandem arc systems, a DC positive electrode is used as

the leading electrode and an AC electrode as the trail.
 SAW PROCESS –
EFFECT OF CURRENT

With wire speed, the welding current increases and thus the
deposition rate increases.

The current density (CD) controls the depth of penetration -

the higher the current density the greater the penetration.

At lower CD, arc stability will be lost and below a minimum

threshold value, an irregular bead is obtained.

Too high a current density also leads to instability because

the electrode overheats and undercutting may also occur.
 SAW PROCESS –
EFFECT OF ELECTRODE DIAMETER

CD = Current/ X-sectional area

For given current, change in the electrode/ wire diameter will

change the current density.

Therefore a larger diameter electrode will reduce penetration

and the likelihood of burn through, but at the same time arc
striking is more difficult and arc stability is reduced.
 SAW PROCESS –
OPERATING CHARACTERISTICS

Operating characteristics of the SAW Process

 SAW PROCESS –
EFFECT OF WELDING SPEED

Welding speed or travel speed controls depth of

penetration. Bead size is inversely proportional to travel
speed.

Faster speeds reduce penetration and bead width, increase

the likelihood of porosity. For an extreme case, produce
undercutting and irregular beads.

At high welding speeds the arc voltage should be kept fairly

low otherwise arc blow is likely to occur.
 SAW PROCESS –
EFFECT OF WELDING SPEED

If the welding speed is too slow burn through can occur.

A combination of high arc voltage and slow welding speed

can produce a mushroom shaped weld bead with
solidification cracks at the bead sides.
 SAW PROCESS –
EFFECT OF ELECTRODE EXTENSION

Electrode extension (EE) also known as electrode stick out

and is measured as the tip to work distance.

EE governs amount of resistance heating in the electrode.

If the extension is short the heating effect is small and the

penetration is deep.

Increasing the extension increases the temperature of the

electrode, which decreases the penetration, but deposition
rates are increased.
 SAW PROCESS –
EFFECT OF ELECTRODE EXTENSION

Increased extension is therefore useful in cladding and

surfacing applications, but steps have to be taken to guide
the electrode, otherwise it wanders.

For normal welding applications, the electrode extension

should be 25 - 30mm for mild steel and less, about 20 -
25mm, for stainless steel.

Reduced extension is recommended for SS is because of the

higher electrical resistance of stainless wire than mild steel
wire.
 SAW PROCESS –
EFFECT OF ELECTRODE ANGLE

Since the angle between the electrode wire and the plate
determines the point of application and direction of the arc
force, it has a profound effect on both penetration and the
undercut.

The figure shows the effect on penetration for horizontal fillet

welds.
 SAW PROCESS –
EFFECT OF ELECTRODE ANGLE

The effect of electrode angle on penetration of butt welds.

 SAW PROCESS –
EFFECT OF FLUX DEPTH

.        
The depth of the flux, or flux burden, is often ignored and
the powder heaped around the wire until the arc is
completely covered.

The flux depth should be just sufficient to cover the arc,

although the point where the electrode enters the flux bed
light reflected from the arc should be just visible.

Too shallow a flux bed gives flash-through and can cause

porosity because of inadequate protection of molten metal.

Too deep a flux bed gives a poor bead appearance and can
lead to spillage on circumferential welds.
 SAW PROCESS –
COMMON PRODUCTS IN OUR RANGE

Carbon steels

High strength steels

Low temperature steels

Hard surfacing & wear resistant applications

Stainless steels
 SAW PROCESS –
APPLICATION RANGE OF OUR PRODUCTS

Pipe mill

Ship building Railways

SAW wire &

Wind mill flux
Power plants
towers

Pressure
Steel plants
vessels
 SAW PRODUCTS –
COMMON APPLICATIONS

Pipe mills F7A2/A4-EM12K Man Industries, PSL

(X42 to X70 pipes)
Railways F7AZ-EL8 Indian railways (RDSO),
F7A2-EM12K DLW
Ship building F7A4-EM12K DGQA, L & T, Hindusthan
Shipyard
Pressure vessels & F7A4-EH14 BEML, L & T, Godrej, INOX
fabrication F7A5 EH10K
Wind mill towers F7A2-EM12K Suzlon Energy
F8A2-EA2
Power plant F7A4-EM12K Thermax, NPCIL, VTV,
F9 P2-EB3 B3 Alstom, BHEL
F8P2-EB2 B2
PENSTOCK EM4 PES ENGINEERING
EF3
 SAW PRODUCTS –
NEW DEVELOPMENTS

SAW SAW
SMAW BRAND NAME AWS CLASS
WIRE FLUX

CROMOTHERME-1 EB2 AUTOTHERME GR-L SAF 13 F8P2EB2-B2

CROMOTHERME-2 EB3 AUTOTHERME GR-M SAF 13 F9P2EB3-B3

CROMOTHERME-1
EB2R AUTOTHERME GR-LR SAF 12 F8P2EB2-B2
RTE

CROMOTHERME-2
EB3R AUTOTHERME GR-MR SAF 12 F9P2EB3-B3
RTE

CROMOTHERME-5 EB6 AUTOTHERME GR-R SAF 12 F8P2EB6-B6

CROMOTHERME-91 EB9 AUTOTHERME GR-N SAF 12 F9PZEB9-B9

 SAW PRODUCTS –
NEW DEVELOPMENTS

SAW SAW
SMAW BRAND NAME AWS CLASS
WIRE FLUX

TENSAL-MH EF3 AUTOTHERME GR-P SAF 10 F9A4EF3-F3

ULTRATENSAL-
EM4 AUTOTHERME GR-Q SAF 10 F11A8EM4-M4
MH

COROTHERME-
EG AUTOTHERME GR-G SAF 11 F8A2EG-G
SPL

NITHERME-2.5 ENi2 AUTOTHERME GR-H SAF 9 F8A5ENi2-Ni2

NITHERME-3.5 ENi3 AUTOTHERME GR-S SAF 10 F8A8/P8ENi3-Ni3

 SAW PRODUCTS –
COMMON EQUIVALENTS

1.0 Acidic Flux to meet 0C and -29C Charpy V-notch Impact Value
1a E6013 Up to 0.70mt/ min welding speed SAF 2 Gr. A F7AZ-EL8

      SAF 2 Gr. B F7AZ-EM12K

      SAF 3 Gr. A F7AZ-EL8

      SAF 3 Gr. B F7A0-EM12K

1b E6013 Up to 1.0 mt/ min welding speed SAF 6 Gr. B F7A2-EM12K

    Up to 1.5 mt/ min welding speed & SAF 7S Gr. A F7AZ-EL8

Multi-wire welding

      SAF 7S Gr. B F7A0-EM12K

 SAW PRODUCTS –
COMMON EQUIVALENTS

2.0 Basic Flux to meet -29C and -40C Charpy V-notch Impact Value
2a E7018 Up to 0.50mt/ min welding speed SAF 4 Gr. B F7A2-EM12K

      SAF 4 Gr. C F7A4-EH14

      SAF 4 (Spl) Gr. B F7A4-EM12K

2b E7018 After SR at 620C for 1-2 hours SAF 4 (Spl) Gr. C F7P4-EH14
with
PWHT
      SAF 4 (Spl) Gr. E F7P4-EH10K

    After SR at 620C up to 6 hours SAF 4 (PW) Gr. C F7P4/ P5-EH14

2c E7018 Up to 1.8 mt/ min welding speed & SAF 223 Gr. B F7A2-EM12K
(high Multi-wire welding
speed
welding)
    SAF 223 Gr. C F7A4-EH14

      SAF 223 Gr. B F7A4-EM12K

(Spl)
 SAW PRODUCTS –
COMMON EQUIVALENTS

3.0 Basic Flux to meet -46C Charpy V-notch Impact Value

E7018-1 (-46C Up to 0.50mt/ min SAF 5S Gr. C F7A5-EH14

impact) welding speed

E7018-1 with PWHT After SR at 620C up SAF 4 (PW) Gr. C F7P4/ P5-
to 6 hours EH14

E7018-1 with NACE   SAF 8 (Spl) Gr. A (spl) F7A5-EL8

    SAF 8 Gr. E F7A6-EH10K

E7018-1 with PWHT After SR at 620C up SAF 8 (LS) Gr. E F7P4/P6-

& NACE to 6 hours EH10K
SAW PROCESS –
COMMON DEFECTS

Cracks

Inclusions/Slag

Porosities

Pock marks

Undercut
 SAW PROCESS –
COMMON DEFECTS

WELD CRACKS

Causes Corrective actions

Too high a weld Increase the arc voltage or
depth-to-width ratio. decrease the welding current.
Too small a weld Decrease the travel speed.
bead.
Rapid cooling of the Hold the arc and not remove
crater at the end of the crater end flux/slag
the weld. immediately.
 SAW PROCESS –
COMMON DEFECTS

INCLUSIONS

Causes Corrective actions

Use of multiple pass, Clean the previous bead before

not cleaning the making subsequent passes.
welding slag.

High travel speeds (film .Reduce the travel speed.

type inclusions). Increase the arc voltage.
 SAW PROCESS –
COMMON DEFECTS

POROSITIES

Causes Corrective actions

Inadequate re-drying of Re-dry as per manufacturer
the flux recommendation.
Reduce travel speed.
Reduce arc gap/ stick out.
Electrode contamination Use clean wires.
Work-piece Clean the job prior to welding.
contamination
 SAW PROCESS –
COMMON DEFECTS

INCOMPLETE FUSION

Causes Corrective actions

Work-piece not clean Clean the job.

Insufficient heat input Increase feed rate.

Reduce travel speed.
Low voltage or current Set the welding parameters.

Improper welding Direct the wire along the

technique groove.
Improper joint design Select proper groove angle.
 SAW PROCESS –
COMMON DEFECTS

LACK OF PENETRATION

Causes Corrective actions

Improper joint preparation Increase root openings.

Reduce the height of root
face.
Improper welding Select proper angle.
technique Direct the wire along the
groove.
Inadequate heat input Increase wire feed rate.
Maintain proper welding
parameters.
 SAW PROCESS –
COMMON DEFECTS

MELT THROUGH

Causes Corrective actions

Excessive heat input Reduce wire feed rate.

Increase travel speed.
Improper joint preparation Reduce excessive root
opening.
Increase the height of root
face.
 SAW PROCESS –
COMMON DEFECTS

Incomplete root penetration Lack of fusion in the root

in butt-weld. run of a fillet-weld.
 SAW PROCESS –
COMMON DEFECTS

Excess penetration in the

root run of a butt-weld
SAW PROCESS –
COMMON DEFECTS
SAW PROCESS –
COMMON DEFECTS
SAW PROCESS –
COMMON DEFECTS
SAW PROCESS –
COMMON DEFECTS
SAW PROCESS –
COMMON DEFECTS
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SAW PROCESS