ELECTROSLAG WELDING

What is electroslag welding ?

Electroslag Welding is a welding process, in which the heat is generated by an electric current passing between the consumable electrode (filler metal) and the work piece through a molten slag covering the weld surface.

(ESW) is similar to electrogas welding, but the main difference is the arc starts in a different location.

process
Prior to welding the gap between the two work pieces is filled with a welding flux. Electroslag Welding is initiated by an arc between the electrode and the work piece (or starting plate). Heat, generated by the arc, melts the fluxing powder and forms molten slag.

 The slag reaches a temperature of about 3500F (1930C). This temperature is sufficient for melting the consumable electrode and work piece edges. Metal droplets fall to the weld pool and join the work pieces. The slag, having low electric conductivity, is maintained in liquid state due to heat produced by the electric current.

Uses
Electroslag welding is used mainly to join low carbon steel plates and/or sections that are very thick. It can also be used on structural steel if certain precautions are observed.

 This process uses a direct current (DC) voltage usually ranging from about 600A and 40-50V, higher currents are needed for thicker materials. Because the arc is extinguished, this is not an arc process.

Advantages High deposition rate - up to 20 kg/h. Low slag consumption (about 5% of the deposited metal weight). Low distortion. Unlimited thickness of work piece.

Disadvantages Coarse grain structure of the weld. Low toughness of the weld. Only vertical position is possible.