WT1 c3 PDF

3.
Submerged Arc Welding
2003
3. Submerged Arc Welding 26
In submerged arc welding a mineral weld flux layer protects the welding point and
the freezing weld from the influence 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-
flux hopper electrode fed wire electrode

are transferred into
contact piece
the weld pool. Un-
fused flux can be
extracted from be-
hind the welding
head and subse-
quently recycled.
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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 car-
ried out via a hose
AC or DC current supply
from the flux con- wire straightener
wire feed rolls
tainer to the feeding flux supply
indicators power source
wire reel welding machine holder
hopper which is
mounted on the
torch head. De-
pending on the de-
gree of automation
it is possible to in-
br-er3-02e.cdr © ISF 2002
stall a flux excess

Assembly of a SA Welding Equipment
pickup behind the
torch. Submerged Figure 3.2
arc welding can be operated using

alloy type commercial wire
electrodes
main alloying elements either an a.c. power source or a d.c.
Mn Ni Mo Cr V
Mn S1 0,5 power source where the electrode is
S2 1,0
S3 1,5 normally connected to the positive
S4 2,0
MnMo S2Mo 1,0 0,5 terminal.
S3Mo 1,5 0,5
S4Mo 2,0 0,5 Welding advance is provided by the
Ni S2Ni1 1,0 1,0
S2Ni2 1,0 2,0 welding machine or by workpiece
NiMo S2NiMo1 1,0 1,0 0,5
S3NiMo1 1,5 1,0 0,5 movement.
NiV S3NiV1 1,5 1,0 0,15
NiCrMo S1NiCrMo2,5 0,5 2,5 0,6 0,8
S2NiCrMo1 1,0 1,0 0,6 0,5
S3NiCrMo2,5 1,5 2,5 0,6 0,8
Identification of wire electrodes for
submerged arc welding is based on
From a diameter of 3 mm upwards all wire electrodes have
to be marked with the following symbols: the average Mn-content and is carried
S1 S6: I IIIIII Example: out in steps of 0.5%, Figure 3.3.
Si : _ S2Si: II _
Mo : S3Mo: III
Standardisation for welding filler ma-
terials for unalloyed steels as well as

for fine-grain structural steels is con-
tained in DIN EN 756, for creep resis-
Figure 3.3
DIN EN 756 Reference Properties and application
mat.-no. analysis
tant steels in DIN pr EN 12070 (previ- approx.
weight %
S1 C = 0,08 For lower welding joint quality requirements;in:
ously DIN 8575) and for stainless and 1.0351 Si = 0,09 boiler and tank construction, pipe production,
Mn = 0,50 structural steel engineering, shipbuilding
heat resistant steels in DIN pr EN S2 C = 0,10 For higher welding joint quality requirements; in:
1.5035 Si = 0,10 pipe production, boiler and tank construction,
Mn = 1,00 sructural steel engineering, shipbuilding.
12072 (previously DIN 8556-10). Fine-grain structural steels up to StE 380.
S3 C = 0,11 For high-quality welds with medium
1.5064 Si = 0,15 wall-thicknesses.
Mn = 1,50 Fine-grain structural steels up to StE 420.
S2Si C = 0,10 Especially suitable for welding of pipe steels,
The proportions of additional alloying 1.5034 Si = 0,30 no tendency to porosity of unkilled steels.
Mn = 1,00 Fine-grain structural steels up to StE 420.
elements are dependent on the mate- S2Mo C = 0,10 For welding in boiler and tank construction and
1.5425 Si = 0,15 pipeline production with creep-resistant steels.
rials to be welded and on the me- Mn = 1,00
Mo = 0,50
Working temperatures of up 500 °C. Suitable
for higher-strength fine-grain structural steels.
S2Ni1 C = 0,09 For welding low-temperature fine-grain
chanical-technological demands which Si = 0,12 structural steels.
Mn = 1,00 Non-ageing.
Ni = 1,20
emerge from the prevailing operating S2Ni2 C = 0,10 Especially suitable for low-temperature welds.
Si = 0,12 Non-ageing.
conditions, Figure 3.4. Connected to Mn = 1,00
Ni = 2,20
S3NiMo1 C = 0,12 For quenched and tempered fine-grain
this, most important alloying ele- Si = 0,15 structural steels.
Mn = 1,00 Suitable for normalising and/or re-quenching
Mo = 0,50 and tempering.
ments are manganese for strength, Ni = 1,00
molybdenum for high-temperature

strength and nickel for toughness.
Figure 3.4
The identification
of wire electrodes
W i r e e l e c t r o d e DIN EN 756 - S2Mo
for submerged arc
welding is stan-
DIN main no.

dardised in DIN EN
756, Figure 3.5.
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
br-er3-05e.cdr
Identification of a Wire Electrode

in Accordance with DIN EN 756
Figure 3.5
During manufacture of fused welding fluxes the individual mineral constituents

are, with regard of their future compo-
lime quarz rutile bauxite magnesite
sition, weighed and subsequently
fused in a cupola or electric furnace,
roasting kiln silos
Figure 3.6. In the dry granulation proc-
balance
ess, the melt is poured stresses break coke
the crust into large fragments. During

raw material coke
water granulation the melt hardens to
molten metal
air
form small grains with a diameter of
tapping
approximately 5 mm. electrical furnace coal-burning stove
granulation tub
foaming air
As a third variant, compressed air is
cylindrical crusher
screen
additionally blown into the water tank
resulting in finely blistered grains with drying oven
low bulk weight. The fragments or balance
grains are subsequently ground and br-er3-06e.cdr © ISF 2002
screened – thus bringing about the

desired grain size.
Figure 3.6
During manufacture of agglomer-

rutile Mn - ore fluorspar magnesite alloys
ated weld fluxes the raw materials
sintering furnace
are very finely ground, Figure 3.7.
silos
ball mill After weighing and with the aid of a
mixer suitable binding agent (waterglass) a
balance
pre-stage granulate is produced in the
dish granulator mixer.
gas
Manufacture of the granulate is fin-
drying oven
ished on a rotary dish granulator

where the individual grains are rolled
heat treatment furnace
up to their desired size and consoli-
screen
date. Water evaporation in the drying
cooling pipe
oven hardens the grains. In the an-
balance nealing furnace the remaining water is
subsequently removed at tempera-

tures of between 500°C and 900°C,
depending on the type of flux.
Figure 3.7
Properties Fused fluxes

1) Agglomerated
1)
The fused welding fluxes are charac- fluxes
terised by high homogeneity, low sen- uniformity of grain

+/++ -/++
size distribution
sitivity to moisture, good storing prop- grain strength +/++ -/++
2)
erties and high abrasion resistance. homogeneity +/++ -- /++
susceptibility
+/++ -/+
An important advantage of the ag- to moisture
storing properties +/++ -/++
glomerated fluxes is the relatively low
resistance to dirt --/+ -/++
manufacturing temperature, Figure current carrying capacity +/++ +/++
3.8. The technological properties of slag removability -/+ +/++

high-speed welding
the welded joint can be improved by properties +/++ +/++
the addition of temperature-sensitive multiple-wire weldability -/++ +/++
deoxidation and alloying constituents flux consumption -/+ +/++

1)
assessment : -- bad, - moderate, + good, ++ very good
to the flux. Agglomerated fluxes have, 2)
core agglomerated flux
in general, a lower bulk weight (lower br-er3-08e.cdr © ISF 2002
consumption) which allows the use of

components which are reacting among
Figure 3.8
themselves during
MnO + SiO2 min. 50% manganese-silicate
MS
CaO max. 15%
CaO + MgO + SiO2 min. 55%
the melting proc-
CS CaO + MgO calcium-silicate
min.15%
ZrO2 + SiO2 + MnO min. 45% ess. However, the
ZS zirconium-silicate
ZrO2 min. 15%
RS
TiO2 + SiO2 min. 50%
rutile-silicate
higher susceptibil-
TiO2 min. 20%
AR Al2O3 + TiO2 min. 40% aluminate-rutilel
Al2O3 + CaO + MgO min. 40%
ity to moisture dur-
AB Al2O3 min. 20% aluminate-basic
CaF2 max. 22% ing storage and-
Al2O3 + SiO 2 + ZrO2 min. 40%
AS CaF2 + MgO min. 30% aluminate-silicate processing has to
ZrO2 min. 5%
AF Al2O3 + CaF2 min. 70% aluminate-fluoride-basic
CaO + MgO + CaF2 + Mo min. 50%
be taken intocon-
FB
SiO2 max. 20% fluoride-basic
CaF2 min. 15% sideration.
Z other compositions
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Different Welding Flux Types

According to DIN EN 760
Figure 3.9
The SA welding fluxes are, in accordance with their mineralogical constituents, clas-
sified 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
MS - high manganese and silicon pickup
- restricted toughness values
- high current carrying capacity/ high weld speed
welding or weld metal properties.
- unsusceptible to pores and undercuts
- unsuitable for thick parts In addition to the groups mentioned
- suitable for high-speed welding and fillet welds
above there is also the Z-group which
CS acidic types
- highest current carrying capacity of all fluxes allows free compositions of the flux.
- high silicon pickup
- suitable for welding by the pass/ capping method of thick
parts with low requirements
basic types
- low silicon pickup The calcium silicate fluxes are rec-
- suitable for multiple pass welding
- current carrying capacity decreases with increaseing
basicity ognized by their effective silicon
ZS - high-speed welding of single-pass welds pickup. A low Si pickup has low crack-
RS - high manganese pickup/ high silicon pickup

ing tendency and liability to rust, on
- restricted toughness values of the weld metal
- suitable for single and multi wire welding the other hand the lower current car-
- typical: welding by the pass/ capping pass method
rying capacity of these fluxes has to
AR - average manganese and silicon pickup
- suitable for a.c. and d.c. be accepted. A high Si pickup leads to
- single and multi wire welding
- application fields: thin-walled tanks, fillet welds for
structural steel construction and shipbuilding a high current currying capacity up to
br-er3-10ae.cdr © ISF 2002
2500 A and a deep penetration. Alu-

minate-basic fluxes have, due to the
higher Mn pickup, good mechanical
Figure 3.10a
properties. With the application of wire

AB - medium manganese pickup
- good weldability electrodes, as S1, S2 or S2Mo, a low
- good toughness values in welding by the pass/ capping
pass method
- application field:unalloyed and low alloyed structural steels cracking tendency can be obtained.
- suitable for a.c. and d.c.
- applicable for multilayer welding or welding by the
pass/ capping pass method
AS - mainly neutral metallurgical behavior

Fluoride-basic fluxes are character-
- manganese burnoff possible
- good weld appearance and slag removability ised by good weld metal impact val-
- to some degree suitable for d.c.
- recommended for multi layer welds for high toughness ues and high cracking insensitivity.
requirements
- application field: high-tensile fine grain structural steels,
pressure vessels, nuclear- and offshore components Figures 3.10a and 3.10b show typical
AF - suitable for welding stainless steels and nickel-base alloys properties and application areas for
- neutral behaviour as regards Mn, Si and other
constituents
the different flux types.
FB - mainly neutral metallurgical behaviour
- however, manganese burnoff possible
- highest toughness values right down to very low
temperatures Figure 3.11 shows the identification
- limited current carrying capacity and welding speed
- recommended for multi layer welds
- application field: high-tensile fine-grain structural steeels
of a welding flux according to DIN
Z - all other compositions EN 760 by the example of a fused
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calcium silicate flux. This type of flux

is suitable for the welding of joints as
well as for overlap welds. The flux can
Figure 3.10b
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 steels. The silicon pickup is 0.1 – 0.3% (6), while the
manganese pickup is expected to be 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 w e l d i n g f l u x D I N EN 760-SF CS 1 67 AC H10
source. The hydro-
gen content in the DIN main no. hydrogen content
(table 4)
clean weld metal is flux/SA welding
type of current
lower than the method of manufacture
F fused metallurgical
A agglomerated behaviour
10 ml/100 g weld M mechanically mixed flux (table 2)
metal. flux type flux class 1-3

(figure 3.9) (table 1)
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Identification of a Welding Flux

Figure 3.11
The flux classes 1-3 (table 1) explain the suitability of a flux for welding certain ma-
terial groups, for welding of joints and for overlap welding. The flux classes also
characterise the metallurgical material behaviour. In table 2 defines the identification
figure for the
table 2
table 1 metallurgial identification proportion flux in

pickup or burn-off
flux class
behaviour figure all-weld metal
1 2 3
unalloyed and
% behaviour of the
low-alloyed steel 1 over 0,7
general 2 0,5 up to 0,7
structural steel burnoff
3 0,3 up to 0,5 respective ele-
high-tensile & creep 4 0,1 up to 0,3
resistant steels
stainless and heat
pickup or
burnoff
5 0 up to 0,1 ment. Table 4
resistant steels
6 0,1 up to 0,3
Cr- & CrNi steels
pickup 7 0,3 up to 0,5 shows the grada-
welding of joints 8 0,5 up to 0,7
9 over 0,7
hardfacing
table 4
tion of the diffus-
pickup of elements hydrogen content
as C, Cr, Mo identification ml/100g all-weld metal ible hydrogen
max.
H5 5
content in the
H10 10
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H15 15 weld metal, Fig-
Parameters for Flux Identification ure 3.12.
Figure 3.12
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
wire-flux combination
D I N E N 7 5 6 - S 4 6 3 AB S2 point of 460 N/mm²
(46) and a mini-
standard no. chemical
composition of mum metal impact
wire electrode and/or the wire electrode
wire-flux combination value of 47 J at –
for submerged arc
welding type of flux 30°C (3). The flux
(figure 3.10)
type is aluminate-
strength and impact energy
fracture strain (table 3) basic (AB) and is
(table1 and 2)
br-er 3-13e.cdr
used with a wire of
Identification of a Wire-Flux Combination the quality S2.

Figure 3.13
The tables for the identification of the tensile properties as well as of the impact en-
ergy are combined in Figure 3.14.
The chemical composition of the weld
table 1 Identification for strength properties of multipass weld joints
identification minimum yield point tensile strength minimum fracture strain

metal and the structural constitution
n/mm2 N/mm2 %
35 355 440 up to 570 22 are dependent on the different metal-
38 380 470 up to 600 20
42 420 500 up to 640 20
lurgical reactions during the welding
46 460 530 up to 680 20
50 500 560 up to 720 18
process as well as on the used mate-
rials, Figure 3.15. The welding flux
Identification for strength properties of welding by the
table 2 pass/ capping pass method welded joints influences the slag viscosity, the pool
minimum base metal minimum tensile
identifi-
yield strength strength
cation
N/mm2 N/mm2 motion and the bead surface. The
2T 275 370
3T 355 470 different combinations of filler material
4T 420 520
5T 500 600 and welding flux cause, in direct de-
pendence on the weld parameters
Identification for the impact energy of clean all-weld metal or of welding by
table 3 the pass/ capping pass method welded joints
(current, voltage), a different melting
identification Z A 0 2 3 4 5 6 7 8
temp. for minimum
impact energy 47J
no
demands +20 0 -20 -30 -40 -50 -60 -70 -80 behaviour and also different chemical
°C
reactions. The dilution with the base
metal leads to various strong weld
pool reactions, this being dependent
on the weld parameters.
Figure 3.14
The diagram of the

characteristics for welding flux welding filler metal
3 different welding droplet reaction welding data
fluxes assists, in
dependence of the base metal
used wire elec- slag dilution welding data
trodes, to determine
the pickup and weld pool reaction welding data
burn-off behaviour
of the element weld metal
br-er 3-15e.cdr
manganese, Figure
Metallurgical Reactions During
3.16. For example: Submerged Arc Welding
A welding flux with Figure 3.15

the mean charac-

Mn-pickup
teristic and when a
wire electrode S3
is used, has a neu-
1,0% 2,0% 3,0% Mn in wire tral point where
S1 S2 S3 S4 S5 S6 neither pickup nor
burn-off occur.
Mn-burnoff
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Manganese-Pickup and Manganese-Burnoff

During Submerged Arc Welding
Figure 3.16
The pickup and burn-off behaviour is, besides the filler material and the welding
flux, also directly dependent on the welding amperage and welding voltage, Figure
3.17. By the example of the selected flux a higher welding voltage causes a more
steeply descending manganese char-
weld flux LW 280
acteristic at a constant neutral point. current intensity 580 A
welding speed 55 cm/min
Silicon pickup increases with the in-
creased voltage. The influence of cur-
neutral point
rent and voltage on the carbon content
is, as a rule, negligible. % Mn wire
pickup/ burnoff rX in weight %
Inversely proportional to the voltage is

the rising characteristic as regards
manganese in dependence on the
% Si wire
welding current, Figure 3.18. Higher
currents cause the characteristic curve
% C wire
to flatten. 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.
Figure 3.17
The Mn-content of the weld metal can be

weld flux LW 280 determined by means of a welding flux
arc voltage 29 V
welding speed 55 cm/min diagram, Figure 3.19.
neutral point
In this example, the two points on the
% Mn wire axis which determine the flux characteris-

pickup/ burnoff rX in weight %
tic are defined for the parameters 600A

450 A welding current and 29V welding voltage,
with the aid of the auxiliary straight line
% Si wire and the neutral point curve (MnNP). In this
case, the two points are positioned at
0.6% ∆Mn and 1.25% MnSZ. Dependent
% C wire
on the manganese content of the used

filler material, the pickup or burn-off con-
tents can be recognized by the reflection

with respect to the characteristic line
Figure 3.18
(0.38% Mn-pickup with a wire contain-

flux diagramm LW 280,
ing 0.5%Mn, 0.2% Mn-burnoff with a manganese
wire electrode 4 mm Ø
wire containing 1.75%Mn). acc. to Prof. Thier
example: I = 580 A
U = 29 V
MnSZ1 = 0.48 % Mn
The structure of the characteristic line MnSZ2 = 1.69 % Mn
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 prop-
erties and therefore no neutral point
exists, the second auxiliary straight
line must be considered for the deter-
mination of the second characteristic br-er3-19e.cdr © ISF 2002
line point.
Figure 3.19
Weld preparations for multipass fabrication are dependent on the thickness of the
plates to be welded, Figure 3.21. If no
root is planned during weld prepara-
flux diagramm LW 280,
silicon tion and also no support of the weld
wire electrode 4 mm Ø
acc. to Prof. Thier pool is made, the root pass must be
example: I = 580 A welded using low energy input.
U = 29 V
SiSZ = 0.16 % Si
auxiliary When welding very thick plates which

straight line
are accessible 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
auxiliary
straight line
and is, as milling is necessary, more
expensive, although exact weld
preparation and correct selection of
the welding parameters lead to a high
Figure 3.20 weld quality.
Another variation of
heavy-plate welded preparation geometry weld buildup
joints is the so-called and manual metal arc welding
SA
“steep single-V butt SA
weld”, Figure 3.23. SA

SA
The very steep edges SA
SA
keep the welding vol-

manual metal arc welding
ume at a very low manual metal arc welding
SA
SA
level. This technique, SA
SA
however, requires the
br-er 3-21e.cdr
application of special
Welding Procedure Sheets for Single-V Butt Welds, Single-Y
narrow-gap torches. Butt Welds with Broad Root Faces and Double-V Butt Welds
The geometry during

Figure 3.21
slag detachment and
also during rework-
preparation geometry weld buildup

ing weld-related
defects may cause
manual metal arc welding problems. Here,
turning and sanding
side 1 manual metal arc welding
SA high demands are
SA
turn
SA
made on torch ma-
SA
turn nipulation and
SA
side 2 SA
turn process control.
SA
SA
Special narrow-gap
br-er3-22e.cdr © ISF 2002 welding fluxes fa-
Welding Procedure Sheet cilitate slag re-
for Double-U Butt Welds
moval.
Figure 3.22
The most important welding parameters as regards weld bead formation are weld-
ing current, voltage and speed, Figure 3.24. A higher welding current causes higher
deposition 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 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
GMA welding
energy per unit
length decreases GMA welding
which leads, be-

SA welding
sides lower
penetration, also to SA welding
narrower beads.
oscillated
Welding Procedure Sheet

for Square-Edge Welds
Figure 3.23
A) flat weld - I square butt joint

2,4
constant: 2,2
consumption kg flux / kg wire

fused composition fluxes
2,0
w 1,8
plate thickness: 1,6
tp wire electrode: 1,4
flux: 1,2
agglomerated fluxes
1,0
penetration depth tp in mm
welding current (I) 0,8

0,6
weld width b in mm
constant: I 0,4
w 0,2
0
tp 400 500 600 700 800 900 1000 1100
current intensity (A)
B) fillet weld
1,6
consumption kg flux/ kg wire

arc voltage (U) 1,4
fused composition fluxes
1,2
1,0
w 0,8
agglomerated fluxes
0,6
te 0,4
constant: I 0,2
0
400 500 600 700 800 900 1000 1100
welding speed (v)
current intensity (A)
br-er3-24e.cdr © ISF 2002 br-er3-25e.cdr © ISF 2002
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 ag-
glomerated fluxes is
direction of welding lower than that of
fused fluxes.
1 2 3
Two different control

concepts allow the
L1
L2
regulation of the arc

L3
length (the principle

is shown in Figure
3.26). The applica-
tion of the appropri-

Control of the Arc Length
ate control system is
Figure 3.26
dependent on the available power

U
U0 source characteristics.
The external regulation of the arc
A I
US length by the control of the wire feed
∆U A´ I´
speed requires a power source with a
∆I
steeply descending characteristic,
IS IK Figure 3.27. In this case, the shorten-

I
external regulation ( ∆ U-regulation) ing of the arc caused by some
U
process disturbance, entails a strong
I
U0 voltage drop at a low current rise. As
A
US A´ I´ a regulated quantity, this voltage drop
reduces the wire feed speed. Thus,
∆U ∆I
the initial arc length can be regulated
IS I at an almost constant deposition rate.
internal self regulation ( ∆ I-regulation)
In contrast, the internal regulation

effects, when the arc is reduced, a
strong current rise at a low voltage
Figure 3.27
drop (slightly descending characteris-

tic). At a constant wire feed speed the backing flux
initial arc length is independently regu-

lated by the increased burn-off rate
which again is a consequence of the
high current.
ceramic backing bar

The reaction of the internal regula-
tion to process disturbance is very
fast. This process is self regulating
and does not require any machine ex- flux copper backing
penditure.
In submerged arc welding of butt br-er3-28e.cdr
joints, it is, depending on the weld Examples of Weld

Pool Backups
preparation, necessary to support the
Figure 3.28
liquid weld pool with a backing, Figure 3.28. This is normally done with either a ce-
ramic or copper backing with a flux layer or by a backing flux. Dependent on the
shape of the backing bar, direct formation of the underside seam can be achieved.
When welding circumferential tubes,
30°
0° -
the inclination angle of the elec-
trode has a direct influence onto the
formation of the weld bead, Figure
3.29. For external as well as for inter-
nal tube welds, the best weld shapes
may be obtained with an adjusted an-
α1 = 0° α2 α3
gular position of the torch. If the ad-
vance is too low, the molten bath runs
ahead and produces a narrow weld
with a medium-sized ridge, too high
b1 b2 b3
an advance causes the flowback of
t3
the molten bath and a wide seam with

t2
t1
a formed trough in the centre. The

inclusion
processes described here for external

tube welds are, the other way round,
also applicable to internal tube welds.
Figure 3.29
To increase the
efficiency of sub-
merged arc weld- single wire tandem
ing, different proc-

ess variations are
applied, Figure
3.30. In multiwire
parallel twin tandem, twin
welding, where up wire wire
to 6 wires are used,

each welding torch
is operated from a Process Variations of

Submerged-Arc Welding
separate power
source. In twin wire Figure 3.30
welding, two wire

electrodes are
connected in one
torch and supplied
iron powder/ cold wire
chopped wire from one power
source. Dependent
on the application,
the wires can be
hot wire strip arranged in a
parallel or in a tan-
Process Variations of dem.

Submerged-Arc Welding
Figure 3.31
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 preheated filler wire (hot wire). The
1. WH 2. WH
use of a rectangular strip instead of a
wire electrode allows a higher current = ~
65°
tandem welding 12..16
carrying capacity and opens the SA
method also for the wide application 1. WH 2. WH 3. WH
range of surfacing. ~ ~
=
65°
three-wire welding 35 12..16
However, the mentioned process
1. WH HW 2. WH 3. WH
variations can be combined over
= ~ ~
wide ranges, where the electrode dis- three-wire, hot wire
15 10 10
welding
tances and positions have to be ap- 35 12..16
propriately optimised, Figure 3.32.

Current type, polarity, geometrical co- ~ ~ ~ ~
80° 75°
ordination of the individual weld heads four-wire welding 15 18 12
and the selected weld parameters also

have substantial influence on the weld
result.
Figure 3.32
The description of these individual

process variations of submerged arc
100
kg/h welding shows that this method can
80
70 be applied sensibly and economically
deposition rate
60 single wire+ metal powder

50 single wire+ hot wire over a very wide operating range,
four-wire
40 double wire
30 Figure 3.33. It is a high-efficiency
three-wire
20
10 tandem welding process with a deposition
single wire
0
0 500 1000 1500 2000 2500 A 3500 rate of up to 100 kg/h. Due to large
current intensity
molten pools and flux application posi-
12
kg/h tional welding is not possible.
9 voltage = 30 V
∅5,0 mm
weld metal
speed = 40 cm/min
∅ 4,0 mm
6 wire protrusion = 10d
length
∅3,0 mm
3~
~
0 300 400 500 600 800
A
current intensity
Figure 3.33
When more than one wire is used in order to obtain a high deposition rate, arc inter-
actions occur due
to magnetic arc
elektrode
blow, Figure 3.34. (_) (_)
Therefore, the + + + _ + ~
selection of the
current type (d.c.
(+) _ _( ) _ + _
or a.c.) and also +
sensible phase arc
displacements
workpiece
between the indi- br-er3-34e.cdr © ISF 2002
vidual welding Magnetic Interaction of Arcs

at SA Tandem Welding
torches are very
important. Figure 3.34

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3.

Submerged Arc Welding

flux hopper electrode fed wire electrode

Process Principle of Submerged Arc Welding

Main components of a submerged arc welding unit are:

stall a flux excess

arc welding can be operated using

terials for unalloyed steels as well as

molybdenum for high-temperature

DIN main no.

Identification of a Wire Electrode

During manufacture of fused welding fluxes the individual mineral constituents

ess, the melt is poured stresses break coke

the crust into large fragments. During

low bulk weight. The fragments or balance

grains are subsequently ground and br-er3-06e.cdr © ISF 2002

screened – thus bringing about the

During manufacture of agglomer-

ished on a rotary dish granulator

subsequently removed at tempera-

Properties Fused fluxes

terised by high homogeneity, low sen- uniformity of grain

3.8. The technological properties of slag removability -/+ +/++

the addition of temperature-sensitive multiple-wire weldability -/++ +/++

deoxidation and alloying constituents flux consumption -/+ +/++

in general, a lower bulk weight (lower br-er3-08e.cdr © ISF 2002

consumption) which allows the use of

Different Welding Flux Types

RS - high manganese pickup/ high silicon pickup

2500 A and a deep penetration. Alu-

properties. With the application of wire

AS - mainly neutral metallurgical behavior

calcium silicate flux. This type of flux

metal. flux type flux class 1-3

Identification of a Welding Flux

table 1 metallurgial identification proportion flux in

Identification of a Wire-Flux Combination the quality S2.

identification minimum yield point tensile strength minimum fracture strain

The diagram of the

3 different welding droplet reaction welding data

used wire elec- slag dilution welding data

A welding flux with Figure 3.15

the mean charac-

Manganese-Pickup and Manganese-Burnoff

Inversely proportional to the voltage is

influence on the location of the neutral

The Mn-content of the weld metal can be

% Mn wire axis which determine the flux characteris-

tic are defined for the parameters 600A

on the manganese content of the used

tents can be recognized by the reflection

(0.38% Mn-pickup with a wire contain-

for the determination of the silicon

auxiliary When welding very thick plates which

weld”, Figure 3.23. SA

keep the welding vol-

The geometry during

also during rework-

preparation geometry weld buildup

which leads, be-

br-er3-23e.cdr © ISF 2002

Welding Procedure Sheet

A) flat weld - I square butt joint