CHAPTER 1

INTRODUCTION
Submerged arc welding (SAW) is a common arc welding process. The first patent on the submerged-arc welding
(SAW) process was taken out in 1935 and covered an electric arc beneath a bed of granulated flux. Originally
developed and patented by Jones, Kennedy and Rothermund, the process requires a continuously fed consumable
solid or tubular (metal cored) electrode. The molten weld and the arc zone are protected from atmospheric
contamination by being "submerged" under a blanket of granular fusible flux consisting of lime, silica, manganese
oxide, calcium floride, and other compounds. When molten, the flux becomes conductive, and provides a current
path between the electrode and the work. This thick layer of flux completely covers the molten metal thus
preventing spatter and sparks as well as suppressing the intense ultraviolet radiation and fumes that are a part of
the shielded metal arc welding (SMAW) process.

SAW is normally operated in the automatic or mechanized mode, however, semi-automatic (hand-held) SAW
guns with pressurized or gravity flux feed delivery are available. The process is normally limited to the flat or
horizontal-fillet welding positions (although horizontal groove position welds have been done with a special
arrangement to support the flux). Deposition rates approaching 45 kg/h (100 lb/h) have been reported — this
compares to 5 kg/h (10 lb/h) (max) for shielded metal arc welding. Although currents ranging from 300 to 2000 A
are commonly utilized, currents of up to 5000 A have also been used (multiple arcs).

Single or multiple (2 to 5) electrode wire variations of the process exist. SAW strip-cladding utilizes a flat strip
electrode (e.g. 60 mm wide x 0.5 mm thick). DC or AC power can be used, and combinations of DC and AC are
common on multiple electrode systems.

Fig. 1.1 Submerged Arc welding

Session 2015-19 Page 1

 CHAPTER 2
FEATURES OF WELDING

A Welding is a common process for joining metals using a large variety of applications. Welding occurs in several
locations, from outdoors settings on rural farms and construction sites to inside locations, such as factories and
job shops. Welding processes are fairly simple to understand, and basic techniques can be learned quickly Welding
is the joining of metals

At the simplest level, welding involves the use of four components: the metals, a heat source, filler metal, and
some kind of shield from the air. The metals are heated to their melting point while being shielded from the air,
and then a filler metal is added to the heated area to produce a single piece of metal. It can be performed with or
without filler metal and with or without pressure at a molecular level.

There are several types of welding that are used today. Gas Metal Arc Welding (GMAW) or MIG, Gas Tungsten
Arc Welding (GTAW) or TIG, Flux Core Arc Welding, and Stick Welding are the most common found types in
industrial environments.

A weld is a homogeneous bond between two or more pieces of metal, where the strength of the welded joint
exceeds the strength of the base pieces of metal.

weld joins metals by applying heat or a filler metal with a high melting point, or both. In Welding, welds and
feature geometry are represented as quilts with a high level of complexity.

Consider the following about the weld feature:

• A weld feature does not change the geometry of welded components. Before you proceed to welding, make sure
components to be welded have appropriate profiles.

• Adding a weld does not merge referenced components. When you retrieve a component that was welded in an
assembly, its geometry remains the same.

• Welds are parametrically defined features. They are associative with the referenced geometry. They can be
manipulated like other standard Creo features.

• Weld faces are represented in the assembly as quilts. A quilt represents a patchwork of connected non-solid
surfaces and can consist of a single surface or a collection of surfaces.

• You cannot remove material from a weld when the feature that removes material, for example, a hole, is created
in a part. Material is removed from the parent part, but the entire weld remains.

Session 2015-19 Page 2

 Fig. 2.1 welding working process

2.1 Types of welding

 Metals inert gas (MIG)

 Arc welding or shielded metal arc welding (SMAW)
 Tungsten inert gas (TIG)
 Flux cored arc welding (FCAW)
 Submerged arc welding (SAW)

 Metals inert gas (MIG)

The concept of combining two pieces of metal together with a wire that is connected to an electrode current, is
referred to as Metal Inert Gas (MIG) welding. In this type of welding process, a shielded gas is used along the wire
electrode, which heats up the two metals to be joined. A constant voltage and direct current power source is required
for this method, and this is the most common industrial welding process. The MIG or GMAW process is suitable for
fusing mild steel, stainless-steel as well as aluminium.
 Arc welding or shielded metal arc welding (SMAW)
Arc welding is also called as Shielded Metal Arc welding, or simply referred to as ‘Stick’. This is the most basic
of all welding types. The welding stick uses electric current to form an electric arc between the stick and
the metals to be joined. To weld iron and steel, this type of welding is often used in the construction of steel

Session 2015-19 Page 3

structure and in industrial fabrication. Stick welding can be used for manufacturing, construction and repair work.

Fig. 2.2 SMAW PROCESS

 Tungsten inert gas (TIG)

Fig.2.3. TIG process

Session 2015-19 Page 4

A non-consumable tungsten electrode is used in this type of welding process. This tungsten electrode is made use of
to heat the base metal and create a molten weld puddle. By melting two pieces of metal together, an autogenous
weld can be created. For this type of welding, the welder needs to have a lot of expertise as it’s a very complex
process. This welding process is employed to carry out high-quality work when a superior standard finish is
required, without making use of excessive clean up by sanding or grinding.

 Flux cored arc welding (FCAW)

As an alternative to shield welding, Flux-cored Arc Welding was developed. This welding process is quite similar to
MIG or GMAW process, except for the fact that in FCAW a special tubular wire filled with flux is used and
shielding gas is not always needed, depending on the filler. This type of welding is well-known for being extremely
inexpensive and easy to learn. However, there are several limitations in its applications and the results are not often
aesthetically pleasing as some of the other welding methods. The semi-automatic arc is often used in construction
projects, thanks to its high welding speed and portability.

Session 2015-19 Page 5

 CHAPTER 3
FEATURE OF SAW

3.1 introduction about SAW

SAW is a good and fast process. The first patent on the submerged-arc welding (SAW) process was taken
out in 1935 and covered an electric arc beneath a bed of granulated flux. Developed by the E O Paton Electric
Welding Institute, Kiev, during the Second World War, SAW's most famous application was on the T34 tank.
Similar to MIG welding, SAW involves an arc between a continuously-fed bare. wire electrode. and the
work piece. The process uses a flux to generate protective gases and slag, and to add alloying elements to the weld
pool. A shielding gas is not required. Prior to welding, a thin layer of flux powder is placed on the work piece
surface. The arc moves along the joint line and as it does so, excess flux is recycled via a hopper. Remaining fused
slag layers can be easily removed after welding. As the arc is completely covered by the flux layer, heat loss is
extremely low. This produces a thermal efficiency as high as 60% (compared with 25% for manual metal arc).
There is no visible arc light, welding is spatter-free and there is no need for fume extraction
According to material thickness, joint type and size of component, varying the following can increase
deposition rate and improve bed shape.

3.2 Principle of SAW

Submerged Arc Welding or SAW is one of the most occurring arc welding process. It needs a electrode which
may be solid of tubular. The electrode should be used in a continuous approach. It should be fed continuously for
your kind information tubular electrode is the one which is flux shielded.
The main feature of this welding is that – The weld and the arc area is protected from environmental contamination
by the application of a granular flux which is fusible. The weld pool is protected by a blanket of flux. So that area is
actually submerged under that flux. When temperature rises and molten the flux becomes conductive. And thus this
creates a path for electron flow between electrode and workpiece. SAW or Submerged Arc welding can be done by
manual procedure or automatic process. But it can be done by semi-automatic process where welding gun is hold by
hand. Here pressurized gravity flux feed is given.
Both DC and AC can be used as power supply. In multiple electrode system DC – AC combination is very
common. Constant voltage power supply machines are used very frequently.
Submerged arc welding (SAW) (Figure 10.1), is a high-productivity method of welding, generally carried out
using mechanical welding methods and suitable for use with 1–3 continuous wire electrodes.

Session 2015-19 Page 6

 Fig. 3.1 principle working of SAW

12

Session 2015-19 Page 7

 3.2 Welding and bonding of SAW

(SAW) is a welding process in which the molten weld and the arc zone are protected from atmospheric
contamination under a fusible flux. The process is normally limited to a horizontal-fillet welding position, but with a
high deposition rate. This welding process is usually applied to carbon steels, low alloy steels, stainless steels, and
nickel-based alloys. Deep weld penetration and thick materials may be welded with this process. For this welding
process Hashemi studied the hardness and the microstructure of the fusion zone, the base metal, and the HAZ of
double submerged arc welded (SAW welding) in a line pipe steel of grade API X65 manufactured and welded by
spiral forming.

The hardness of the FZ was slightly higher than the hardness of the base metal and this can be attributed to the
presence of lower temperature transformation products (i.e. bandinite Widman statten ferrite) in the FZ. The
microstructure showed that the HAZ did not experience melting, but its microstructure changed due to phase
transformation. In this case, the base metal region remained unaffected. The flux starts depositing on the joint to be
welded. Since the flux when cold is non-conductor of electricity, the arc may be struck either by touching the
electrode with the work piece or by placing steel wool between electrode and job before switching on the welding
current or by using a high frequency unit. In all cases the arc is struck under a cover of flux.

Flux otherwise is an 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 work piece through the molten flux. The upper portion of
the flux, in contact with atmosphere, which is visible remains granular (unchanged) and can be reused. The lower,
melted flux becomes slag, which is waste material and must be removed after welding.

The electrode at a predetermined speed is continuously fed to the joint to be welded. In semi-automatic welding
sets the welding head is moved manually along the joint. In automatic welding a separate drive moves either the
welding head over the stationary job or the job moves/rotates under the stationary welding head.

The arc length is kept constant by using the principle of a self-adjusting arc. If the arc length decreases, arc
voltage will increase, arc current and therefore burn-off rate will increase thereby causing the arc to lengthen. The
reverse occurs if the arc length increases more than the normal.

Session 2015-19 Page 8

.

Fig. 3.2 process on work piece

Session 2015-19 Page 9

 3.4 Types of SAW
Single wired

 Single wired welding is the most widely used SAW method.

 DC power source is used.
 The solid or cored wired of diameter 2.0-4.0mm
 A small diameter produces a higher deposition at the higher deposition at same rate .

Fig. 3.3 single wire SAW

Session 2015-19 Page 10

 Double wired
 For twin wire welding, two wires are connected to the same power source.
 DC power used
 It offers upto 30% higher deposition rate and can be used on higher electric
current and speeds.
 Very high welding speeds can be achieved in fillet welding.

Fig. 3.4 Twin wire SAW

Tandom wire

 The tandom wire sub arc welding each of fed two wire is connected to its own power source
an e simuataneousy by its own feed unit.

 Both Ac an DC power source be used.

 The Wires are normally large diameter (3.0-5.0mm) and deposition rates are about twice that
of single wire welding.

Session 2015-19[Type text] Page 11

 .

Fig. 3.5 tandom wire SAW

Tandom twin

 The tandom twin process involves two twin wire heads placed in sequence.
 Both AC and DC source can be used.
 With the use of 4*2.5mm diameter, wires deposition rates upto 38 kg/h can be achieved.

Multi wire

 Upto six wires can be used together, each with their own power source.
 The lead wire is usually DC+ polarity with the trailing wires being AC.
 Speeds off upto 2.5 m/min can be achieved giving a maximum deposition rate of 90 kh/h
 This technique is particularly suitable for longitudinal pipe welding.

Session 2015-19 Page 19

 Fig. 3.5 Multiwire SAW

Fig. 3.6 Tandom twin SAW

[Type text] Page 20

 CHAPTER 4
Components of SAW

Welding equipment used for submerged arc welding systems consist of three components: the
powder feeder, the wire feeder, and the welding power source. Depending on degree of
mechanization, there is also the means for the movement of the welding head and the welding
portion. The welding powder is fed from a reservoir via pipes and hoses to the fusion point
where the welding head is in the powder bed. Unused powder lies loosely on the solid slag layer
and can be extracted with a trailer, and returned to the circulation. The wire feed consists of the
wire feed motor and the two feed rollers, between which the wire passes. One of the rollers is
located on the motor shaft and causes the removal of the wire from the reel. The second roll acts
as a counter-pressure roller. The speed at which the wire is fed must be controlled so that the
length of the arc to the desired welding current results. When submerged arc welding is
dependent on the welding flux used with both DC and AC, working with AC, so will the power
sources have a falling characteristic. Welding rectifiers for submerged arc welding have a
strong decline to constant static characteristics. The static characteristic of the welding power
source used is strongly affected by the type of control. When submerged arc welding is
preferably carried out with the so-called external control (ΔU control), the arc voltage controls
the speed of the wire feed motor. The current needs to fit through a corresponding change so the
characteristic curve can be selected. The control is affected, depending on the voltage over the
wire feed, by which is connected to the change in the arc length control voltage change of the
wire feed speed ΔU. The single-wire – a wire electrode and a power source – may be used as
partial or fully mechanized procedures. To increase the deposition rate, a number of variants
for submerged arc welding were developed. In double wire submerged arc welding, also
occasionally referred to as a parallel-wire welding, two wires are melted together or one after
the other in the welding joint. Both electrodes are located on a power source, and are fed
together and burning in an arc. The advantages are a higher deposition rate compared to the
single wire, and a better degassing of the melt, due to the fact that the bath is greater, and thus
more slowly, and solidifies at a higher welding speed.
The tandem welding electrodes are arranged in succession in the welding direction. They each
have their own power source with its own rules (Figure 36). By the separate control, it is
possible to achieve a deep penetration with the first electrode at high amperage, so that while
operating at a plurality of electrodes with the final electrode with a higher voltage, a good weld
surface is produced. The tandem system has been extended to multi-wire systems with up to
four electrodes. Another variation is hot wire welding. In addition to the arc melting electrode, a
second wire is supplied with its own power source and its own control. This wire is directly
next to the arc contact with the work piece, and this area is heated by resistance heating to red
heat. Reached the so heated wire portion of the arc, it is sealed there. The advantage of this

Session 2015-19 Page 23

arrangement is that with a relatively small electrical power, a high deposition rate can be
achieved.

Welding head
It feeds flux and filler metal to the welding joint. Electrode (filler metal) gets energized here.
Flux hopper
It stores the flux and controls the rate of flux deposition on the welding joint.
Flux
The granulated flux shields and thus protects molten weld from atmospheric contamination. The
flux cleans weld metal and can also modify its chemical composition. The flux is granulated to
a definite size. It may be of fused, bonded or mechanically mixed type. The flux may consist of
fluorides of calcium and oxides of calcium, magnesium, silicon, aluminium and manganese.
Alloying elements may be added as per requirements. Substances evolving large amount of
gases during welding are never mixed with the flux. Flux with fine and coarse particle sizes are
recommended for welding heavier and smaller thickness respectively.
Fluxes Most metals in their molten state are oxidized by the atmospheric oxygen. Flux is a
chemical compound used to prevent this oxidation and other unwanted chemical reactions.
They help to make the welding process easier and ensure a sound weld. Fluxes for Submerged
Arc Welding usually consist of metallic oxides such as CaO, MgO and FeO and fluorides such
as CaF2. It is specially formulated to be compatible with a given electrode wire so that the
combination of flux and wire yields desired mechanical properties, all fluxes react with the
weld pool to produce the weld metal chemical composition and mechanical properties. Like the
manual electrode coating, the SAW Flux can incorporates alloying elements so that in
combination with an unalloyed wire it yields suitably alloyed weld metal. The molten slag also
provides favourable conditions for very high current densities which together with the
insulating properties with the flux, concentrate heat into a relatively small welding zone, This
results in a deep penetrating arc which makes narrower and shallower welding grooves
practicable and reducing the amount of weld metal required to complete the joint as well as
provides higher welding speeds. The properties of the flux enable Submerged Arc Welds to be
19 made over a wide range of welding currents, voltage and speeds, each can be controlled
independently from other and welded joints of desired shapes, chemistry and mechanical
properties can be obtained by using an appropriate welding procedure. The SAW flux is so
formulated, not to emit appreciable amount of gases under intense heat of welding zone, it is in
granular form and capable of flowing freely through the flux feeding tubes, valves and nozzles
of standard welding equipment. The flux in its solid state is a non-conductor of electricity but in
molten condition becomes a highly conducting medium. It is necessary to initiate the arc by
special means. Once the arc is struck and the surrounding flux becomes molten, the welding
current continues to flow across the arc while the Arc provides a conducting path of molten flux
as it advances. The flux contains elements capable of assisting in the initial striking of Arc and
stabilizing it later. It is common practice to refer fluxes as 'active' if it added manganese and
silicon to the weld, the amount of addition of manganese and silicon is influenced by the Arc
voltage and the welding current.
SAW fluxes can be classified into two main groups:
 According to the method of manufacturing

Session 2015-19 Page 24

 According to the chemical nature
The chemical nature of a welding flux can be expressed as the basicity or Basicity index.
CaO+ MgO+ CaF2 +Na2O+N2O+1/2(MnO+FeO) B (Basicity) =
SiO2+1/2(Al2O3+TiO2+ZrO2)
The formula for Basicity or Basicity index is based upon the ratio of basic oxides to acidic
oxides.
Electrode
SAW filler material usually is a standard wire as well as other special forms. This wire
normally has a thickness of 1.6 mm to 6 mm (1/16 in. to 1/4 in.). In certain circumstances,
twisted wire can be used to give the arc an oscillating movement. This helps fuse the toe of the
weld to the base metal. The electrode composition depends upon the material being welded.
Alloying elements may be added in the electrodes. Electrodes are available to weld mild steels,
high carbon steels, low and special alloy steels, stainless steel and some of the nonferrous of
copper and nickel. Electrodes are generally copper coated to prevent rusting and to increase
their electrical conductivity. Electrodes are available in straight lengths and coils. Their
diameters may be 1.6, 2.0, 2.4, 3, 4.0, 4.8, and 6.4 mm. The approximate value of currents to
weld with 1.6, 3.2 and 6.4 mm diameter electrodes are 150–350, 250–800 and 650–1350 Amps
respectively.
Size of Electrode For a given welding current, a decrease of wire diameter results in an increase
in current density. This results in a weld with a deeper penetration and reduced width. The
submerged arc welding process usually employs wires of 2 to 5 mm diameter. A wire diameter
2 to 3 mm is best suited for deeper penetration at low currents.
Electrode Stick out:It is also termed as electrode extension. It refers to the length of electrode
between the end of the contact tube and the arc column, which is subjected to resistance heating
at the high current densities used in the process. The longer the stick out, the increase in
deposition rate is accompanied by a decrease in penetration, Longer stick-out is avoided when
deep penetration is desired

Session 2015-19 Page 25

Fig. 4.1 welding head of SAW

Fig. 4.2 flux

Fig. 4.3 electrode

Session 2015-19 Page 26

 Fig. 4.4 flux hopper

ELECTRICITY
Welding Current: It controls the melting rate of the electrode, weld deposition rate as well as
depth of penetration. Too high a current causes excessive weld reinforcement, burn of thinner
plates and badly fitted joints, excessive current also produces narrow deep beads and undercut.
Excessively low current gives an unstable. arc and overlapping. SAW control panel is usually
provided with an ammeter to monitor and control the welding current.

Welding Voltage: The arc voltage varies in direct proportion to the arc length. With the
increase in arc length the arc voltage increases and thus more heat is available to melt the metal
and the flux. However, increase in Arc length means more spread of the Arc column; this leads
to increase in weld width and volume of reinforcement while the depth of penetration decreases.
The arc voltage varies with the welding current and wire diameter.

Welding Operation
The flux starts depositing on the joint to be welded. Since the flux when cold is non-conductor
of electricity, the arc may be struck either by touching the electrode with the work piece or by
placing steel wool between electrode and job before switching on the welding current or by
using a high frequency unit. In all cases the arc is struck under a cover of flux. Flux otherwise is
an 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 workpiece through the molten flux.

Session 2015-19 Page 27

The upper portion of the flux, in contact with atmosphere, which is visible remains granular
(unchanged) and can be reused. The lower, melted flux becomes slag, which is waste material
and must be removed after welding.
The electrode at a predetermined speed is continuously fed to the joint to be welded. In semi-
automatic welding sets the welding head is moved manually along the joint. In automatic
welding a separate drive moves either the welding head over the stationary job or the job
moves/rotates under the stationary welding head.
The arc length is kept constant by using the principle of a self-adjusting arc. If the arc length
decreases, arc voltage will increase, arc current and therefore burn-off rate will increase thereby
causing the arc to lengthen. The reverse occurs if the arc length increases more than the normal.
A backing plate of steel or copper may be used to control penetration and to support large
amounts of molten metal associated with the process.

Material applications

 Carbon steels (structural and vessel construction)

 Low alloy steels
 Stainless steels
 Nickel-based alloys
 Surfacing applications (wear-facing, build-up, and corrosion resistant overlay of steels)

Carrier:
Used to provide the base for movement of the saw on a workpiece. By this SAW can move in
any direction easly and fast.
Carrier are 2 types
 Horizontal motion carrier
 Vertical motion carrier

Roller:
It used to continuously and exact feeding of electrode for welding in SAW. It can be manual or
automatic feed equipment and have a major role in perfect welding, without it we can not get a proper
and satisfactory welding on work piece.

Fig 4.5 Roller

Session 2015-19 Page 28

 CHAPTER 5

5.1 WORKING OF SAW

Submerged-arc welding (SAW) involves the formation of an arc between a continuously fed
wire and the workpiece. A blanket of powdered flux creates a protective gas shield and a slag
for the weld zone. A shielding gas is not required. The arc is submerged beneath the flux
blanket and is not normally visible during welding.

SAW is normally operated in the automatic or semi-automatic mode. The process is

normally limited to the flat or horizontal-fillet welding positions.
submerged Arc Welding is a welding process, which utilizes a bare consumable metallic
electrode producing an arc between itself and the work piece within a granular shielding
flux applied around the weld.
The arc heats and melts both the work pieces edges and the electrode wire. The molten
electrode material is supplied to the surfaces of the welded pieces, fills the weld pool and joins
the work pieces.
Since the electrode is submerged into the flux, the arc is invisible. The flux is partially melts
and forms a slag protecting the weld pool from oxidation and other atmospheric
contaminations.
The flux starts depositing on the joint to be welded. Since the flux when cold is non-conductor
of electricity, the arc may be struck either by touching the electrode with the work piece or by
placing steel wool between electrode and job before switching on the welding current or by
using a high frequency unit. In all cases the arc is struck under a cover of flux. Flux otherwise is
an 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 work piece through the molten flux.
The upper portion of the flux, in contact with atmosphere, which is visible remains granular
(unchanged) and can be reused. The lower, melted flux becomes slag, which is waste material
and must be removed after welding.
The electrode at a predetermined speed is continuously fed to the joint to be welded. In semi-
automatic welding sets the welding head is moved manually along the joint. In automatic
welding a separate drive moves either the welding head over the stationary job or the job
moves/rotates under the stationary welding head.
The arc length is kept constant by using the principle of a self-adjusting arc. If the arc length
decreases, arc voltage will increase, arc current and therefore burn-off rate will increase thereby
causing the arc to lengthen. The reverse occurs if the arc length increases more than the normal.
A backing plate of steel or copper may be used to control penetration and to support large
amounts of molten metal associated with the process. Throughout the submerged arc welding
process, the flux has to be a continuously-fed tubular or consumable solid electrode. This
fusible flux may consist of lime, silica, manganese oxide, calcium fluoride, and other
compounds. In a molten or melted state, the flux becomes conductive. This allows it to supply
a constant current between the electrode and the welding work.

Session 2015-19 Page 29

 Fig. 5.1 working of SAW

Session 2015-19 Page 30

 Fig. 5.2 process on workpiece

Session 2015-19 Page 31

 Fig. 5.3 process on head

Session 2015-19 Page 32

 CHAPTER 6

Applications of SAW
It is generally used to weld thicker section steels for longitudinal and circumferential ‘Butt’ and ‘Fillet’
welds. However, because of high fluidity of the weld pool, molten slag and loose flux layer, welding is
generally carried out on butt joints in the flat position and fillet joints in both the flat and horizontal-
vertical positions. For circumferential joints, the work piece is rotated under a fixed welding head with
welding taking place in the flat position. Depending on material thickness, either single-pass, two-pass
or multi-pass weld procedures can be carried out. There is virtually no restriction on the material
thickness, provided a suitable joint preparation is adopted. Most commonly welded materials are plain
carbon steel, carbon manganese steels, low alloy steels and stainless steels, although the process is
capable of welding some non-ferrous materials with judicious choice of electrode filler wire and flux
combinations. Major application in industry 28 Used to build up parts and overlays with stainless or
wear resistant steels
 .Manufacturing of ships, heavy structural components of bridges
 It is widely used for the repairing of machine parts by depositing cladding andhard-facing
beads.
 Fabrication of pipes, penstocks, pressure vessels, boilers, railroad, structure of railway coaches
and locomotives. Automobile, Aviation and Nuclear Industry.
 For welding mild steels, medium & high tensile low alloy steels it is most commonly used.

Material applications

 Carbon steels (structural and vessel construction)

 Low alloy steels
 Stainless steels
 Nickel-based alloys
 Surfacing applications (wear-facing, build-up, and corrosion resistant overlay of steels)

 SAW is ideally suited for longitudinal and circumferential butt and fillet welds. However, because
of high fluidity of the weld pool, molten slag and loose flux layer, welding is generally carried out
on butt joints in the flat position and fillet joints in both the flat and horizontal-vertical positions.
 For circumferential joints, the workpiece is rotated under a fixed welding head with welding taking
place in the flat position.
 Depending on material thickness, either single-pass, two-pass or multipass weld procedures can be
carried out.
 There is virtually no restriction on the material thickness, provided a suitable joint preparation is
adopted.
 Most commonly welded materials are carbon-manganese steels, low alloy steels and stainless steels,
although the process is capable of welding some non-ferrous materials with judicious choice of
electrode filler wire and flux combinations.

Session 2015-19 Page 33

 CHAPTER 7
Advantages of saw
ome of the advantages of submerged arc welding include:

 Strong, sound welds are readily made

 Minimal welding fume is emitted
 Minimal arc light is emitted
 SAW is suitable for both indoor and outdoor works
 Less distortion
 Deep weld penetration
 Minimal edge preparation
 High deposition rates are possible
 Thick materials may be weldedAt least half or more of the flux is recoverable
 Molten flux provides very suitable conditions for high current to flow. Great intensities
of heat can be generated and kept concentrated to weld thicker sections with deep
penetration
 Because of high heat concentration, considerably higher welding speeds can be caused.
 Because of high heat concentration and high welding speeds weld distortion is much
less.
 High metal deposition rates cane be achieved. Single pass welds can be made in thick
plates with normal equipment.
 Welding is carried out without sparks, smoke, flash or spatter.
 Weld metal deposit possesses uniformity, good ductility, corrosion resistance and good
impact strenght.
 Very neat appearance and smooth weld shapes can be got.
 The submerged process can be used for welding in exposed areas with relatively high
winds.
 Practically, no edge preparation is necessary for materials under 12 mm in thickness.

Session 2015-19 Page 34

 CHAPTER 8
Disadvantages of SAW
 Since the operator cannot see the welding being carried out, he cannot judge the
progress of welding accurately. Therefore accessories like jigs and fixtures, pointers,
light beam focusing devices or roller guides may be used for proper welding at the joint
 The flux needs replacing of the same on the joint which is not always possible.
 The progress is limited to welding in flat position and on the metal more than 4.8
mm thick. In small thicknesses burn through is likely to occur.
 The process requires edge preparation and accurate fit up on the joint. Otherwise the
flux may spill through the gap and arc may burn the workpiece edges.
 One issue is that welding can normally be performed only in the flat position. The use of a
granular flux and the fluidity of the molten weld pool mean that welding is limited to
positions 1F, 1G, and 2F.

 Another disadvantage of SAW is that welding is normally limited to long, straight seams or
rotated vessels or pipes. Flux handling systems can be quite bothersome, as well.

Session 2015-19 Page 35

 CHAPTER 9

Uses of SAW
Submerged Arc Welding or SAW is one of the most occurring arc welding process. It needs
a electrode which may be solid of tubular. The electrode should be used in
a continuous approach. It should be fed continuously. Ohhh ... for your kind information tubular
electrode is the one which is flux shielded.

The main feature of this welding is that – The weld and the arc area is protected from
environmental contamination by the application of a granular flux which is fusible. The weld
pool is protected by a blanket of flux. So that area is actually submerged under that flux. When
temperature rises and molten the flux becomes conductive. And thus this creates a path for
electron flow between electrode and workpiece. SAW or Submerged Arc welding can be done
by manual procedure or automatic process. But it can be done by semi-automatic process where
welding gun is hold by hand. Here pressurized gravity flux feed is given.

Both DC and AC can be used as power supply. In multiple electrode system DC – AC

combination is very common. Constant voltage power supply machines are used very
frequently.

o This welding process has high deposit rate. Almost 45kg/h can be deposited.
o In mechanized applications.
o Very little welding fume is seen . .
o No edge preparation is needed.
o This process is applicable indoor as well as outdoor.
o No chance of weld spatter as it is submerged in flux blanket.

o Operation is limited to some specific metals.

o The application is limited to straight seams and pipes and vessels.
o The flux handling can be tough.
o Health issue can be caused because of the flux.
o Slag removal is needed after welding.

Session 2015-19 Page 36

 o Joining of pressure vessels such as boilers.
o Many structural shapes, earth moving equipment, pipes.
o Railroad construction, locomotives and ship building.
o Repairing machine parts.

Because of these properties submerged arc welding is used for industrial purposes and in
manufacturing and also used in maintanance sector of metals.

Fig. 9.1 semi automatic SAW

Session 2015-19 Page 37

 Fig. 9.2 automatic SAW

Fig. 9.3 schematic diag. of SAW

Fig. 9.4 units of SAW

Session 2015-19 Page 38

 CONCLUSION
In response to heightened concern about global environmental problems, demand for natural
gas is increasing year by year10). The CO2 emission per unit of heating value, expressed as the
ratio of coal: crude oil: natural gas, is generally said to be 100: 80: 5011). According to a trial
calculation12), global demand for natural gas in 2035 is expected to reach as much as 1.6 times
the level in 2009. Based on this, continuing increases in the requirements for high strength and
heavy wall thickness linepipe for natural gas are expected. Moreover, the trend toward higher
strength is not limited to the energy transportation field; remarkable increases in the strength of
steel materials have also been seen in construction, shipbuilding, offshore structures, and other
fields. In responding to the even higher strength levels expected in the future, the low heat input
welding method described in this paper will of course be utilized, and use of new welding
technologies such as high energy density beam welding by fiber laser welding systems, etc., and
friction stir welding is also expected. The authors will work to ensure that it is possible to meet
customer needs by utilizing more advanced technologies.

Session 2015-19 Page 39

 REFRENCE
 WIKIPEDIA
 Manufacturing process books
 Faculties of college
 In response to heightened concern about global environmental problems, GAO Peng. “Natural
Gas Pipeline Network Construction in CNPC: Current Status and Trends.” 2013-09-24–26. 3)
Makino, H.
 Evaluating methods of the propagating shear fracture in natural gas pipeline (Lecture for
practical engineer) . Journal of the Japan Welding Society. 2007, vol. 76. no. 2, p. 114–117.e

Session 2015-19 Page 40