Professional Documents
Culture Documents
The main advantage of using the submerged arc welding (SAW) process is high quality and productivity. The
process can be implemented in three different operational modes — semiautomated, mechanized, and
automated.
The main disadvantage of submerged arc welding is that it can be used only in the flat or horizontal welding
positions (test positions 1G or 2G) for plate and pipe welding.
Weld Quality
Because of the excellent protection of the weld metal by the blanket of molten slag, SAW can produce high-
quality welds with fewer weld defects than other processes. However, as in other processes with many
combinations of variables, the problems of porosity, slag inclusions, incomplete fusion, and cracking also occur in
SAW. The following are some of these problems and remedies.
Porosity
Welding metal deposited by SAW is usually clean and free of harmful porosity, but when porosity does occur, it
may be found on the weld bead surface or beneath a sound surface. Possible causes of porosity include the
following:
1. Contaminants in the joint such as paint residue, hydrocarbons from oil-based products, or manufacturing
coatings;
2. Electrode contamination such as rust oils from improper storage;
3. Insufficient flux coverage;
4. Contaminants in the flux, especially in recycled fluxes that may be reused without proper screening;
5. Entrapped slag at the bottom of the joint;
6. Segregation of constituents in the weld metal;
7. Wrong welding parameters, such as high voltage and excessive travel speed, which cause fast solidification
and prevents gases from escaping;
8. Slag residue that has oxidized from tack welds made with covered electrodes (residue may also form gases,
inhibit fusion, and create voids);
9. Moisture in the flux, which can create both hydrogen and oxygen gas pockets;
10. High flux burden; and
11. Arc blow.
As with other welding processes, the base metal and electrode must be clean and dry in SAW. High travel
speeds and associated fast weld metal solidification do not provide time for gas to escape from the molten weld
metal. The travel speed can be reduced, but other solutions should be investigated first to avoid higher welding
costs. Porosity from covered electrode tack welds can be avoided by using electrodes that leave no porosity-
causing residue. Recommended tack weld electrodes are E6010, E6011, E7015, E7016, and E7018.
Inclusions
An inclusion in a weld is defined as the entrapment of solid foreign materials, such as slag, flux, or oxide. As with
all flux-shielded processes, SAW, if not properly applied, is not immune to slag inclusions. Inclusions can be found
primarily in the root overlap or between previous passes, and generally near bevel or groove faces. The risk of
inclusions is greater under the following circumstances:
1. In downhill orientations, which may allow the molten flux to race ahead of the weld pool and then roll under
to become entrapped during solidification;
2. In grooves along the edges of previously deposited beads, especially if they are convex;
3. If there is undercut along the edges of the weld beads;
4. When arc destabilization inhibits the slag from rising to the top of the solidifying weld pool;
5. When a flux too high in viscosity is used, impeding the solidification of the weld pool;
6. When a clean prior bead surface is not maintained;
7. In the case of improper welding head displacement, particularly in the downhill orientation;
8. In the case of reduced penetration due to reduced heat input, supplemental wires or powders, increased
electrode extension, excessive travel speed, or reduced arc density; and
9. In the case of excessive travel speed, which causes faster cooling and may inhibit the slag from rising to the
top of the weld pool.
Incomplete Fusion
Attend Exhibit Conference Exhibitor Directory Hotel & Travel About
As with porosity and inclusions, incomplete fusion can occur at any depth of the weld. It can occur between
either the present or previous beads or the bead and the bevel or groove faces. Specific conditions may foster
incomplete fusion. Most of these are conditions that inhibit the melting and the fusible contact between surfaces,
including the following:
Cracking
Weldment cracking is generally considered the most serious of discontinuities because of the potential for
catastrophic service failure and the often-experienced difficulty in radiographic inspection. Cracking can be
categorized according to several criteria, including location (weld metal, heat-affected zone, or base metal
cracking [hot or cold cracking]), but it is generally assumed to have two basic causes — an imposed strain and
an inability to accommodate that strain.
The types of hot cracking include solidification, liquation, and stress-relief cracking. This discontinuity is usually
associated with the weld metal. Several conditions associated with strains and the ability to accommodate them,
predominantly of cross-sectional geometry and chemistry, are listed as follows:
1. Excess depth-to-width ratio (high penetration processes with single-pass procedures such as SAW are
especially susceptible);
Excessive heat input may decrease the cooling rate and increase the time for metallurgical reactions in a crack-
susceptible temperature range.
Like hot cracking, cold cracking manifests itself in a number of ways. These include hydrogen-induced cracking
or stress-corrosion cracking. Most cold cracking is associated with the heat-affected zone, base metal, or weld
metal.
Excerpted from the AWS Welding Handbook, Ninth Edition, Volume 2, Welding Processes, Part 1.
POSTED IN FABTECH365
North America's largest metal forming, fabricating, welding and finishing event heads to Chicago at McCormick Place in
September 2021. FABTECH provides a convenient "one stop shop" venue where you can meet with world-class suppliers,
see the latest industry products and developments, and find the tools to improve productivity, increase profits and
discover new solutions to all of your metal forming, fabricating, welding and finishing needs.
EXHIBIT ATTEND
SIGN UP ⟶
Attend Exhibit Conference Exhibitor Directory Hotel & Travel About
ATTEND EXHIBIT CONFERENCE HOTEL & TRAVEL ABOUT FAQS CONTACT
North America’s largest metal forming, fabricating, welding and finishing event heads to the Las Vegas Convention Center in
2020. FABTECH provides a convenient ‘one stop shop’ venue where you can meet with world-class suppliers, see the latest
industry products and developments, and find the tools to improve productivity, increase profits and discover new solutions to all
of your metal forming, fabricating, welding and finishing needs.
© 2020 FABTECH. All rights reserved. Privacy Notice. Terms and Conditions.