3.

Submerged Arc Welding

3. Submerged Arc Welding

32

In submerged arc welding a mineral weld flux layer protects the welding point and the freezing weld from the influx hopper electrode contact piece

fluence of the surrounding atmosphere, Figure 3.1. The arc burns in a cavity filled with ionised gases and vapours where the droplets from the continuously-fed wire electrode are transferred into the weld pool. Unfused flux can be extracted from behind the welding head and subsequently recycled.

flux solid slag

arc weld metal

base metal

liquid slag

molten pool

weld cavity

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ISF 2002

Process Principle of Submerged Arc Welding

Figure 3.1 Main components of a submerged arc welding unit are:

the wire electrode reel, the wire feed motor equipped with grooved wire feed rolls which are suitable for the demanded wire diameters, a wire straigthener as well as a torch head for current transmission, Figure 3.2. Flux supply is carried out via a hose from the flux container to the feeding hopper which is mounted on the torch head. Depending on the degree of automation it is possible to install a flux excess pickup behind the torch. Submerged arc
AC or DC current supply wire straightener wire feed rolls flux supply indicators power source wire reel welding machine holder

welding can be operated using either an a.c. power source or a d.c. power source where the electrode is normally connected to the positive terminal. Welding advance is provided by the welding ma-

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ISF 2002

chine
Assembly of a SA Welding Equipment

or

by

workpiece

movement.

Figure 3.2
2005

3. Submerged Arc Welding

33

Identification of wire electrodes for submerged arc welding is based on the average Mncontent and is carried out in steps of 0.5%, Figure 3.3. Standardisation for welding filler materials for unalloyed steels as well as for fine-grain structural steels is contained in DIN EN 756, for creep resistant steels in DIN pr EN 12070 (previously DIN 8575) and for stainless and heat resistant steels in DIN pr EN 12072 (previously DIN 8556-10). The proportions of additional alloying elements are dependent on the materials to be welded and on the mechanical-technological demands which emerge from the prevailing operating conditions, Figure 3.4. Connected to this, most important alloying elements are manganese for strength, molybdenum for high-temperature strength and nickel for toughness.
DIN EN 756 Reference analysis mat.-no. approx. weight % S1 C = 0,08 1.0351 Si = 0,09 Mn = 0,50 S2 1.5035 C = 0,10 Si = 0,10 Mn = 1,00 C = 0,11 Si = 0,15 Mn = 1,50 C = 0,10 Si = 0,30 Mn = 1,00 C = 0,10 Si = 0,15 Mn = 1,00 Mo = 0,50 C = 0,09 Si = 0,12 Mn = 1,00 Ni = 1,20 C = 0,10 Si = 0,12 Mn = 1,00 Ni = 2,20 C = 0,12 Si = 0,15 Mn = 1,00 Mo = 0,50 Ni = 1,00

Properties and application

alloy type Mn

commercial wire electrodes S1 S2 S3 S4 S2Mo S3Mo S4Mo S2Ni1 S2Ni2 S2NiMo1 S3NiMo1 S3NiV1 S1NiCrMo2,5 S2NiCrMo1 S3NiCrMo2,5

main alloying elements Mn Ni Mo Cr V 0,5 1,0 1,5 2,0 1,0 1,5 2,0 1,0 1,0 1,0 1,5 1,5 0,5 1,0 1,5 1,0 2,0 1,0 1,0 1,0 2,5 1,0 2,5 0,6 0,8 0,6 0,5 0,6 0,8 0,5 0,5 0,15 0,5 0,5 0,5

For lower welding joint quality requirements;in: boiler and tank construction, pipe production, structural steel engineering, shipbuilding For higher welding joint quality requirements; in: pipe production, boiler and tank construction, sructural steel engineering, shipbuilding. Fine-grain structural steels up to StE 380. For high-quality welds with medium wall-thicknesses. Fine-grain structural steels up to StE 420. Especially suitable for welding of pipe steels, no tendency to porosity of unkilled steels. Fine-grain structural steels up to StE 420. For welding in boiler and tank construction and pipeline production with creep-resistant steels. Working temperatures of up 500 C. Suitable for higher-strength fine-grain structural steels. For welding low-temperature fine-grain structural steels. Non-ageing. Especially suitable for low-temperature welds. Non-ageing.

MnMo

S3 1.5064 S2Si 1.5034

Ni NiMo NiV NiCrMo

S2Mo 1.5425

S2Ni1

S2Ni2

From a diameter of 3 mm upwards all wire electrodes have to be marked with the following symbols: S1 Si Mo S6: I : _ : IIIIII Example: S2Si: II _ S3Mo: III
ISF 2002

S3NiMo1

For quenched and tempered fine-grain structural steels. Suitable for normalising and/or re-quenching and tempering.
ISF 2002

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Wire Electrodes for Submerged Arc Welding

Properties and Application Areas for Wire Electrodes in Submerged Arc Welding

Figure 3.3

Figure 3.4

The identification of wire electrodes for submerged arc welding is standardised in DIN EN 756, Figure 3.5. During manufacture of fused welding fluxes the individual mineral constituents are, with regard of their future composition, weighed and subsequently fused in a cupola or electric furnace, Figure 3.6. In the dry granulation process, the melt is poured stresses break the
2005

3. Submerged Arc Welding

34

crust into large fragments. During water granulation the melt hardens to form small grains with a diameter of approximately 5 mm.
Wire electrode DIN EN 756 - S2Mo

As a third variant, compressed air is additionally

DIN main no.

blown into the water tank resulting in finely blistered grains with low bulk weight. The fragments or grains are subsequently ground and screened thus bringing about the desired grain size.

Symbols of the chemical composition: S0, S1...S4, S1Si, S2Si, S2Si2, S3Si, S4Si, S1Mo,..., S4Mo, S2Ni1, S2Ni1.5, S2Ni2, S2Ni3, S2Ni1Mo, S3Ni1.5, S3Ni1Mo, S3Ni1.5Mo
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Identification of a Wire Electrode in Accordance with DIN EN 756

Figure 3.5

lime

quarz

rutile

bauxite

magnesite

rutile

Mn - ore

fluorspar

magnesite

alloys

roasting kiln

silos balance coke

sintering furnace silos ball mill mixer balance

raw material molten metal

coke dish granulator air gas drying oven coal-burning stove

tapping electrical furnace granulation tub foaming cylindrical crusher screen cooling pipe air

heat treatment furnace screen

drying oven

balance
br-er3-06e.cdr ISF 2002 br-er3-07e.cdr

balance
ISF 2002

Production of Fused Welding Fluxes

Production of Agglomerated Welding Fluxes

Figure 3.6

Figure 3.7

2005

3. Submerged Arc Welding

35 During manufacture of agglomerated weld

Properties

Fused fluxes1)

Agglomerated fluxes1) -/++ -/++ --2)/++ -/+ -/++ -/++ +/++ +/++ +/++ +/++ +/++

fluxes the raw materials are very finely ground, Figure 3.7. After weighing and with the aid of a suitable binding agent (waterglass) a pre-stage granulate is produced in the mixer. Manufacture of the granulate is finished on a rotary dish granulator where the individual grains are rolled up to their desired size and consolidate. Water evaporation in the drying oven hardens the grains. In the annealing furnace the remaining water is subsequently removed at temperatures of between 500 C and 900 C, depending on the type of flux. The fused welding fluxes are characterised by high homogeneity, low sensitivity to moisture, good storing properties and high abrasion re-

uniformity of grain size distribution grain strength homogeneity susceptibility to moisture storing properties resistance to dirt current carrying capacity slag removability high-speed welding properties multiple-wire weldability flux consumption
1) 2)

+/++ +/++ +/++ +/++ +/++ --/+ +/++ -/+ +/++ -/++ -/+

assessment : -- bad, - moderate, + good, ++ very good core agglomerated flux

ISF 2002

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Properties of Fused and Agglomerated Welding Fluxes

Figure 3.8

sistance. An important advantage of the agglomerated fluxes is the relatively low manufacturing temperature, Figure 3.8. The technological properties of the welded joint can be improved by the addition of temperature-sensitive deoxidation and alloying constituents to the flux. Agglomerated fluxes have, in general, a lower bulk weight (lower consumption) which allows the use of components which are reacting among themselves during the melting process. However, the higher susceptibility to moisture during storage andprocessing has to be taken intoconsideration.
MS CS ZS RS AR AB MnO + SiO2 CaO CaO + MgO + SiO2 CaO + MgO ZrO2 + SiO2 + MnO ZrO2 TiO2 + SiO2 TiO2 Al2O3 + TiO2 Al2O3 + CaO + MgO Al2O3 CaF2 Al2O3 + SiO2 + ZrO2 CaF2 + MgO ZrO2 Al2O3 + CaF2 CaO + MgO + CaF2 + Mo SiO2 CaF2 other compositions min. 50% max. 15% min. 55% min.15% min. 45% min. 15% min. 50% min. 20% min. 40% min. 40% min. 20% max. 22% min. 40% min. 30% min. 5% min. 70% min. 50% max. 20% min. 15% manganese-silicate calcium-silicate zirconium-silicate rutile-silicate aluminate-rutilel aluminate-basic

AS AF FB Z

aluminate-silicate aluminate-fluoride-basic fluoride-basic

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Different Welding Flux Types According to DIN EN 760

Figure 3.9
2005

3. Submerged Arc Welding The SA welding fluxes are, in accordance with their mineralogical constituents, classified into nine groups, Figure 3.9. The composition of the individual flux groups is to be considered as in principle, as fluxes which belong to the same group may differ substantially with regards to their welding or weld metal properties. In addition to the groups mentioned above there is also the Z-group which allows free compositions of the flux. The calcium silicate fluxes are recognized by their effective silicon pickup. A low Si pickup has low cracking tendency and liability to rust, on the other hand the lower current carrying
AB - medium manganese pickup - good weldability - good toughness values in welding by the pass/ capping pass method - application field:unalloyed and low alloyed structural steels - suitable for a.c. and d.c. - applicable for multilayer welding or welding by the pass/ capping pass method - mainly neutral metallurgical behavior - manganese burnoff possible - good weld appearance and slag removability - to some degree suitable for d.c. - recommended for multi layer welds for high toughness requirements - application field: high-tensile fine grain structural steels, pressure vessels, nuclear- and offshore components - suitable for welding stainless steels and nickel-base alloys - neutral behaviour as regards Mn, Si and other constituents
ZS RS CS MS - high manganese and silicon pickup - restricted toughness values - high current carrying capacity/ high weld speed - unsusceptible to pores and undercuts - unsuitable for thick parts - suitable for high-speed welding and fillet welds

36

acidic types - highest current carrying capacity of all fluxes - high silicon pickup - suitable for welding by the pass/ capping method of thick parts with low requirements basic types - low silicon pickup - suitable for multiple pass welding - current carrying capacity decreases with increaseing basicity - high-speed welding of single-pass welds - high manganese pickup/ high silicon pickup - restricted toughness values of the weld metal - suitable for single and multi wire welding - typical: welding by the pass/ capping pass method - average manganese and silicon pickup - suitable for a.c. and d.c. - single and multi wire welding - application fields: thin-walled tanks, fillet welds for structural steel construction and shipbuilding
ISF 2002

AR

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Classification of Fluxes for SA Welding According to DIN EN 760 (I)

Figure 3.10a capacity of these fluxes has to be accepted. A high Si pickup leads to a high current currying capacity up to 2500 A and a deep penetration. Aluminate-basic fluxes have, due to the higher Mn pickup, good mechanical properties. With the application of wire electrodes, as S1, S2 or S2Mo, a low cracking tendency can be obtained. Fluoride-basic fluxes are characterised by good weld metal impact values and high cracking insensitivity. Figures 3.10a and 3.10b show typical properties and application areas for the different flux types.

AS

AF

FB - mainly neutral metallurgical behaviour - however, manganese burnoff possible - highest toughness values right down to very low temperatures - limited current carrying capacity and welding speed - recommended for multi layer welds - application field: high-tensile fine-grain structural steeels Z - all other compositions
ISF 2002

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Classification of Fluxes for SA Welding According to DIN EN 760 (II)

Figure 3.10b

2005

3. Submerged Arc Welding

37

Figure 3.11 shows the identification of a welding flux according to DIN EN 760 by the example of a fused calcium silicate flux. This type of flux is suitable for the welding of joints as well as for overlap welds. The flux can be used for SA welding of unalloyed and low-alloy steels, as, e.g. general structural steels, as well as for welding high-tensile and creep resistant while steels. the The silicon pickup is 0.1 0.3% (6),
welding flux DIN EN 760-SF CS 1 67 AC H10

manganese

pickup is expected to be
DIN main no. flux/SA welding method of manufacture
F fused A agglomerated M mechanically mixed flux

hydrogen content
(table 4)

0.3 0.5% (7). Either d.c. or a.c. can be used, as, in principle, a.c. weldability allows also for d.c. power source. The hydrogen content in the clean weld metal is lower than the 10 ml/100 g weld metal.

type of current metallurgical behaviour

(table 2)

flux type
(figure 3.9)

flux class 1-3

(table 1)

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Identification of a Welding Flux According to DIN EN 760

Figure 3.11 The flux classes 1-3 (table 1) explain the suitability of a flux for welding certain material groups, for welding of joints and for overlap welding. The flux classes also characterise the metallurgical material betable 2 table 1
unalloyed and low-alloyed steel general structural steel high-tensile & creep resistant steels stainless and heat resistant steels Cr- & CrNi steels welding of joints hardfacing pickup of elements as C, Cr, Mo

flux class 1 2 3

metallurgial behaviour

identification proportion flux in all-weld metal figure % 1 2 3 4 5 6 7 8 9 over 0,7 0,5 up to 0,7 0,3 up to 0,5 0,1 up to 0,3 0 up to 0,1 0,1 up to 0,3 0,3 up to 0,5 0,5 up to 0,7 over 0,7

haviour. In table 2 defines the identification figure for the pickup or burn-off behaviour of the respective element. Table 4 shows the gradation of the diffusible hydrogen content in the weld metal, Figure 3.12.

burnoff pickup or burnoff pickup table 4 identification H5 H10 H15

hydrogen content ml/100g all-weld metal

max.

5 10 15

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Parameters for Flux Identification According to DIN EN 760

Figure 3.12

2005

3. Submerged Arc Welding

38

Figure 3.13 shows the identification of a wire-flux combination and the resultant weld metal. It is a case of a combination for multipass SA welding where the weld metal shows a minimum yield point of 460 N/mm (46) and a minimum metal impact value of 47 J at 30 C (3). The flux type is aluminate-basic (AB) and is used with a wire of the quality S2. The tables for the identification of the tensile properties as well as of the impact energy are combined in Figure 3.14. Figure 3.13
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wire-flux combination DIN EN 756 - S 46 3 AB S2

standard no. wire electrode and/or wire-flux combination for submerged arc welding strength and fracture strain
(table1 and 2)

chemical composition of the wire electrode type of flux

(figure 3.10)

impact energy
(table 3)

Identification of a Wire-Flux Combination According to DIN EN 756

The chemical composition of the weld metal and the structural constitution are dependent on the different metallurgical reactions during
table 1
identification Identification for strength properties of multipass weld joints minimum yield point n/mm2 tensile strength minimum fracture strain % N/mm2

the welding process as well as on the used materials, Figure 3.15. The welding flux influences the slag viscosity, the pool motion and the bead surface. The different combinations of filler material and welding flux cause, in direct dependence on the weld parameters (current, voltage), a different melting behaviour and also different chemical reactions. The dilution with the base metal leads to various strong weld pool reactions, this being dependent on the weld parameters. The diagram of the characteristics for 3 dif ISF 2002

35 38 42 46 50

355 380 420 460 500

440 up to 570 470 up to 600 500 up to 640 530 up to 680 560 up to 720

22 20 20 20 18

table 2 identification 2T 3T 4T 5T

Identification for strength properties of welding by the pass/ capping pass method welded joints

minimum base metal yield strength N/mm2 275 355 420 500

minimum tensile strength N/mm2 370 470 520 600

table 3

Identification for the impact energy of clean all-weld metal or of welding by the pass/ capping pass method welded joints

identification temp. for minimum impact energy 47J C

Z
no demands

A +20

0 0

-20 -30 -40 -50 -60 -70 -80

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ferent welding fluxes assists, in dependence of the used wire electrodes, to determine the pickup and burn-off behaviour of the element

Parameter for Weld Metal Identification According to DIN EN 756

Figure 3.14
2005

3. Submerged Arc Welding

39 manganese, Figure 3.16.

welding flux droplet reaction

welding filler metal welding data

For example: A welding flux with the mean characteristic and when a wire electrode S3 is used, has a neutral point where neither pickup nor burn-off occur.

base metal slag dilution welding data

weld pool reaction

welding data

The pickup and burn-off

weld metal
br-er 3-15e.cdr

behaviour is, besides the filler material and the welding flux, also directly dependent on the welding amperage and welding

Metallurgical Reactions During Submerged Arc Welding

Figure 3.15

voltage, Figure 3.17. By the example of the selected flux a higher welding voltage causes a more steeply descending manganese characteristic at a constant neutral point. Silicon pickup increases with the increased voltage. The influence of current and voltage on the carbon content is, as a rule, negligible. Inversely proportional to the voltage is the rising characteristic as regards manganese in dependence on the welding
Mn-pickup

current,

Figure

3.18.

Higher currents cause the characteristic curve to flat1,0% S1 S2 S3 2,0% S4 S5 3,0% Mn in wire S6

ten. As the welding voltage, the welding current also has practically no influence on the location of the neutral point. Silicon pickup decreases with increasing current intensity.

Mn-burnoff
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Manganese-Pickup and Manganese-Burnoff During Submerged Arc Welding

Figure 3.16

2005

3. Submerged Arc Welding

40

weld flux LW 280 (DIN EN 760 SF CS 1 76 AC H 10) current intensity 580 A welding speed 55 cm/min
0,6 % Mn 0,2 0 -0,2 -0,4 -0,6 0,6 % Si 0,2 0 -0,2 -0,4 0,05 0 -0,05 -0,10 -0,15
br-er3-17e.cdr ISF 2006

weld flux LW 280 (DIN EN 760 SF CS 1 76 AC H 10) arc voltage 29 V welding speed 55 cm/min
0,6 % Mn 0,2 0 -0,2 450 A 650 A 700 A 0,5 1,0 % Mn wire 2,0 2,5 800 A 580 A neutral point

33 V

36 V neutral point

25 V 0,5 1,0 % Mn wire 2,0 27 V 29 V 2,5

X in weight %

X in weight %

-0,4 -0,6 0,6 % Si 0,2 0 -0,2 -0,4 0,05 0 -0,05 -0,10 -0,15 800 A

36 V

450 A

25 V 0,05 0,1 0,15 0,2 0,25 0,3 0,35 0,4 0,45 % Si wire

pickup/ burnoff

pickup/ burnoff

0,05 0,1 0,15 0,2 0,25 0,3 0,35 0,4 0,45 % Si wire

800 A 0,15 450 A 0,20 0,25 % C wire

0,05 25 - 36 V

0,15

0,20 0,25 % C wire

% XSZ
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Pickup and Burnoff Behaviour in Dependence on Welding Voltage and Wire Electrode

Pickup and Burnoff Behaviour in Dependence on Welding Current and Wire Electrode

Figure 3.17

Figure 3.18

The Mn-content of the weld metal can be deflux diagramm LW 280

(DIN EN 760 SF CS 1 76 AC H 10),

termined by means of a welding flux diagram, Figure 3.19. In this example, the two points on the axis which determine the flux characteristic are defined for the parameters 580A welding current and 29V welding voltage, with the aid of the auxiliary straight line and the neutral point curve (MnNP). In this case, the two points are positioned at 0.6% Mn and 1.25% MnSZ. Dependent on the manganese content of the used filler material, the pickup or burn-off

manganese
wire electrode 4 mm acc. to Prof. Thier example: I = 580 A U = 29 V MnSZ1 = 0.48 % Mn MnSZ2 = 1.69 % Mn

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ISF 2002

contents can be recognized by the reflection with respect to the characteristic line (0.38%

Welding Flux Diagramm for Determination of the Mn Content in the Weld Metal

Figure 3.19

2005

3. Submerged Arc Welding

41

Mn-pickup with a wire containing 0.5%Mn, 0.2% Mn-burnoff with a wire containing 1.75%Mn). The structure of the characteristic line for the determination of the silicon pickup content, is, in principle, exactly the same as described above, Figure 3.20. As silicon has only pickup properties and therefore no neutral point exists, the second auxiliary straight line must be considered for the determination of the second characteristic line point. Weld preparations for multipass fabrication are dependent on the thickness of the plates to be welded, Figure 3.21. If no root is
auxiliary straight line
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flux diagramm LW 280

(DIN EN 760 SF CS 1 76 AC H 10),

silicon
wire electrode 4 mm acc. to Prof. Thier example: I = 580 A U = 29 V SiSZ = 0.16 % Si
auxiliary straight line

planned during weld preparation and also no support of the weld pool is made, the root pass must be welded using low energy input.
Welding Flux Diagram for Determination of the Si Content in the Weld Metal

Figure 3.20 from both sides, the double-U butt weld may be applied, Figure 3.22. Before the opposite side is welded, the root must be milled out (gouging/sanding). This type of weld cannot be produced by flame cutting and is, as milling is necessary, more expensive, although exact weld preparation and correct selection of the welding parameters lead to a high weld quality.

When welding very thick plates which are accessible

preparation geometry

weld buildup
and

manual metal arc welding

SA SA SA SA SA SA

manual metal arc welding manual metal arc welding

SA SA SA SA

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Welding Procedure Sheets for Single-V Butt Welds, Single-Y Butt Welds with Broad Root Faces and Double-V Butt Welds

Figure 3.21

2005

3. Submerged Arc Welding

42 Another variation of heavy-

preparation geometry

weld buildup

plate welded joints is the so-called steep single-V

manual metal arc welding turning and sanding manual metal arc welding
SA SA

side 1

butt weld, Figure 3.23. The very steep edges keep the welding volume at a very low level. This technique, however, requires the application of special

turn
SA SA

turn turn

side 2

SA SA SA SA

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ISF 2002

narrow-gap torches. The geometry during slag detachment and also during reworking weld-related de-

Welding Procedure Sheet for Double-U Butt Welds

Figure 3.22

fects may cause problems. Here, high demands are made on torch manipulation and process control. Special narrow-gap welding fluxes facilitate slag removal. The most important welding parameters as regards
GMA welding

weld bead formation are welding current, welding voltage current and speed, Figure 3.24. A higher causes higher deposition

GMA welding

SA welding

SA welding oscillated
br-er3-23e.cdr ISF 2002

rates and energy input, which leads to reinforced beads and a deeper penetration. The weld width remains roughly constant. The increased welding voltage leads to a longer arc

Welding Procedure Sheet for Square-Edge Welds

Figure 3.23

which also causes the bead to be wider. The change in welding speed causes - on both sides of an optimum - a decrease of the penetration depth. At lower weld speeds, the weld pool running ahead of the welding arc acts as a buffer between arc and base metal. At high speeds, the energy per unit length decreases which leads, besides lower penetration, also to narrower beads.

2005

3. Submerged Arc Welding

43

w tp 400

20
plate thickness: 25 mm 10 wire electrode: 4 mm flux: MS-Typ

consumption kg flux / kg wire

12 10 8 6 4 2 0

constant:

U = 32 Volt v = 60 cm/min

30

penetration depth tp in mm

500 600 welding current (I)

700

800 Amp.

12 10 8 6 4 2 0

constant: II= 600 Amp.

v = 60 cm/min tp

weld width w in mm

2,4 2,2 2,0 1,8 1,6 1,4 1,2 1,0 0,8 0,6 0,4 0,2 0

A) flat weld - I square butt joint

fused composition fluxes

agglomerated fluxes

400

500

600

700

800 900 1000 1100 current intensity (A)

28

30

32

34

36

38

40 Volt

arc voltage (U) 12 10 w 8 6 te 4 constant: I I = 600 Amp. 2 U = 32 Volt 0 30 40 50 60 70

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consumption kg flux/ kg wire

30 20 10

1,6 1,4 1,2 1,0 0,8 0,6 0,4 0,2 0 400

B) fillet weld fused composition fluxes

agglomerated fluxes

80

90

100

110 cm/min
ISF 2002

500

600

700

welding speed (v)

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800 900 1000 1100 current intensity (A)

ISF 2002

Influence of the Weld Parameters on Penetration Depth and Weld Width

Welding Flux Consumption in Dependence on Current Intensity and Seam Shape

Figure 3.24

Figure 3.25

Weld flux consumption is dependent on the selected weld type, Figure 3.25. Due to geometrical shape, the flux consumption of a fillet weld is significantly lower than that of a butt weld. Because of their lower bulk weight, the specific consumption of agglomerated fluxes is lower than that of fused
direction of welding

fluxes. Two different control concepts allow the regulation of the arc length (the prin-

L1

L2

ciple is shown in Figure

L3

3.26). The application of the appropriate control system is dependent on the available power source

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ISF 2002

Control of the Arc Length

characteristics.

Figure 3.26
2005

3. Submerged Arc Welding The external regulation of the arc length by the control of the wire feed speed requires a power source with a steeply descending characteristic, Figure 3.27. In this case, the shortening of the arc caused by some process disturbance, entails a strong voltage drop at a low current rise. As a regulated quantity, this voltage drop reduces the wire feed speed. Thus, the initial arc length can be regulated at an almost constant deposition rate. In contrast, the internal regulation effects, when the arc is reduced, a strong current rise at a low voltage drop (slightly descending characteristic). At a constant wire feed speed the inibr-er3-27e.cdr

44

U U0 US A DU A I I

DI IS IK
external regulation ( D U-regulation)

U U0 US I A A DI IS
internal self regulation ( D I-regulation)
ISF 2002

DU

tial arc length is independently regulated by the increased burn-off rate which again is a consequence of the high current. Figure 3.27

Control System for Constant Length of Arc

backing flux

The reaction of the internal regulation to process disturbance is very fast. This process is self regulating and does not require any machine expenditure.

ceramic backing bar

In submerged arc welding of butt joints, it is, depending on the weld preparation, necessary to support the liquid weld pool with a backing, Figure 3.28. This is normally done

flux copper backing

with either a ceramic or copper backing with a flux layer or by a backing flux. Dependent on the shape of the backing bar, direct formation

br-er3-28e.cdr

of the underside seam can be achieved.

Examples of Weld Pool Backups

When welding circumferential tubes, the inclination angle of the electrode has a direct

Figure 3.28
2005

3. Submerged Arc Welding

45 influence onto the formation of the weld bead,

3 0 -

Figure 3.29. For external as well as for internal tube welds, the best weld shapes may be obtained with an adjusted angular position of the torch. If the advance is too low, the molten bath runs ahead and produces a narrow weld with a medium-sized ridge, too high an ad-

a1 = 0

a2

a3

vance causes the flowback of the molten bath and a wide seam with a formed trough in the centre. The processes described here for external tube welds are, the other way round,
b1 b2 b3

also applicable to internal tube welds.

t1 t2 t3

inclusion
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To increase the efficiency of submerged arc welding, different process variations are applied, Figure 3.30. In multiwire welding, where up to 6 wires are used, each welding torch is operated from a separate power

Wire Position in SA-Welding for Circumferential Tube Welds

Figure 3.29

source. In twin wire welding, two wire electrodes are connected in one torch and supplied from one power source. Dependent on the application, the wires can be arranged in a parallel or in a tandem. In submerged arc welding with iron powder addition can the deposition rate be substantially increased at constant electrical parameters, Figure 3.31. The increased deposition rate is realised by either the addition of a currentless wire (cold wire) or of a prebr-er3-30e.cdr ISF 2002

single wire

tandem

parallel twin wire

tandem, twin wire

heated filler wire (hot wire). The use of a rectangular Figure 3.30

Process Variations of Submerged-Arc Welding

2005

3. Submerged Arc Welding

46 strip instead of a wire electrode allows a higher current carrying capacity and opens the SA method also

iron powder/ chopped wire

cold wire

for the wide application range of surfacing. However, the mentioned

hot wire

strip

process variations can be combined over wide

ISF 2002

br-er3-31e.cdr

Process Variations of Submerged-Arc Welding

ranges, where the electrode distances and positions have to be appropriately optimised, Figure

Figure 3.31

3.32. Current type, polarity, geometrical co-ordination of the individual weld heads and the selected weld parameters also have substantial influence on the weld result.

1. WH

2. WH
100 kg/h

~ 65 12..16

tandem welding

deposition rate

80 70 60 50 40 30 20 10
0

single wire+ metal powder single wire+ hot wire double wire three-wire tandem single wire four-wire

1. WH =

2. WH ~ 35

3. WH ~ 65

three-wire welding
1. WH =

12..16 HW 2. WH 3. WH ~ ~

500

1000

1500

2000

2500

3500

current intensity
12 kg/h

weld metal

three-wire, hot wire welding

15

10 10 35 12..16

9 6

5,0 mm 4,0 mm

voltage = 30 V speed = 40 cm/min wire protrusion = 10d length

~ 80

~ 15 18

~ 75 12
ISF 2002

3,0 mm 3~ ~ 0 300 400 500 600

800

four-wire welding
br-er3-32e.cdr

current intensity
br-er3-33e.cdr ISF 2002

Position of Wire Electrode in Submerged-Arc Multi-Wire Welding

Application Fields for Submerged-Arc Process Variants

Figure 3.32

Figure 3.33
2005

3. Submerged Arc Welding

47

The description of these individual process variations of submerged arc welding shows that this method can be applied sensibly and economically over a very wide operating range, Figure 3.33. It is a high-efficiency welding process with a deposition rate of up to 100 kg/h. Due to large molten pools and flux application positional welding is not possible. When more than one wire is used in order to obtain a high deposition rate, arc interactions occur due to magnetic arc blow, Figure 3.34. Therefore, the selection of the current type (d.c. or a.c.) and also
arc

(_) +

(_) +

elektrode

(+) _

_( ) +

sensible phase displacements between the indibr-er3-34e.cdr

workpiece
ISF 2002

vidual welding torches are very important. Figure 3.34

Magnetic Interaction of Arcs at SA Tandem Welding

2005