Materials Today: Proceedings xxx (xxxx) xxx

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Materials Today: Proceedings

journal homepage: www.elsevier.com/locate/matpr

A review paper on effect of input welding process parameters on

structure and properties of weld in submerged arc welding process
Harsh Sharma, Balram Rajput, Rudra Pratap Singh
Department of Mechanical Engineering, GLA University, Mathura 281406, India

a r t i c l e i n f o a b s t r a c t

Article history: Joining of materials with the help of submerged arc welding machine is widely used in the concerned
Received 30 December 2019 industries. The quality of the weld is identified by several welding output parameters like weld width,
Accepted 13 February 2020 re-inforcement height, depth of penetration, hardness, impact strength and tensile strength etc. The input
Available online xxxx
welding parameters on which outputs depend are welding current, voltage, feed rate, speed of welding,
electrode extension, diameter of electrode and electrode angle etc. All the researchers try to optimize
Keywords: these parameters according to the concerned requirement. In this review paper it was tried to consider
Process Parameters
different research papers containing the research and analysis made on input output parameters of sub-
Cooling rate
Submerged Arc Welding
merged arc welding process. This paper also focused on analysis of some research papers containing heat
Current input rate, cooling rate of weld, micro structure of weld and heat affected zone and their effect on the
Micro-structure performance of the joint. Total 28 research papers were selected for our consideration after a thorough
HAZ investigation of several such papers. After the analysis of the research papers the future scope of research
was also suggested.
Ó 2020 Elsevier Ltd. All rights reserved.
Selection and of the scientific committee of the 10th International Conference of Materials Processing and
Characterization.

1. Introduction
Submerged Arc Welding is an automatic or semiautomatic
welding process which comes under category of arc welding pro-
cesses. In this process arc is maintained in between the bare con-
sumable electrode and workpiece in a protective inert gas
atmosphere. In this welding we can have high material deposition
rate. This process suits well for working in horizontal position. The
basic difference of this process with the other welding processes is
that in this process the arc is fully submerged inside the granular
flux and is not visible. Heat loss can be minimized using this pro-
cess and a thermal efficiency of more than 90% can be achieved
in this process. In this process automatic wire feed mechanism,
constant voltage power source, digital controls etc are required,
which in turn lead to the requirement of constant and uniform
power supply source. Automatic wire feed mechanism provides
the filler wire as required to the weld. The granular flux is contin-
uously poured on the arc from the hopper in a controlled way so
that the welding is performed in a more efficient and effective
manner. The granular flux provides a shielding atmosphere for
the weld zone. Weld made by submerged arc welding has high
strength and ductility with low hydrogen and nitrogen contents.
This welding process is commonly used in applications where butt
weld configurations or fillet weld with grooves are required. This
process finds its application in automobile industries, rail road
equipment industries, large engineering structure making indus-
tries, shipbuilding industry, pressure vessel fabrication industry,
pipe welding and for storage tanks. Different welding parameters
affect the weld quality and heat affected zone in a varying manner,
which depends upon the amount of variation in parameters like
welding current, voltage, wire feed rate, type of flux used and
welding conditions etc.
2. Principle of working
Submerged arc welding is commonly used in industries where
thick steel sheets are involved or where long welds are required.
The process consists in creating a welded joint between steel com-
ponents using an electric arc submerged beneath a layer of granu-
lar flux. Submerged-arc welding (SAW) involves the formation of
an arc between a continuously fed wire and the work piece. A blan-
ket of granular flux creates a protective shield for the work piece

https://doi.org/10.1016/j.matpr.2020.02.422
2214-7853/Ó 2020 Elsevier Ltd. All rights reserved.
Selection and of the scientific committee of the 10th International Conference of Materials Processing and Characterization.

Please cite this article as: H. Sharma, B. Rajput and R. P. Singh, A review paper on effect of input welding process parameters on structure and properties of
weld in submerged arc welding process, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.02.422
2 H. Sharma et al. / Materials Today: Proceedings xxx (xxxx) xxx
and a slag for the weld zone. A shielding gas is not required. The arc
which is submerged beneath the flux blanket is normally not visi-
ble 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. The submerged arc welding set
up and its block diagrams are shown in Figs. 2.1 and 2.2
respectably.
3. Important terms influence in SAW
3.1. Arc voltage
The arc voltage is a very important parameter in any welding
process as it decides the weld width and input energy for the weld.
3.2. Welding current
Its importance can be understood with its capacity to increase
depth of penetration of the weld which provides the strength of
the weld.
3.3. Welding speed
Speed of electrode wire relative to work piece is termed as
welding speed. Depth of penetration decreases with increase of
speed which results in wider weld width. If the welding speed is
very less, the opposite effect is also observed as at very low speed
the energy transfer to more depth is prevented by the existing mol-
ten weld pool and depth of penetration reduces. For maximum
required depth of penetration the knowledge of optimum speed
is necessary.
3.4. Wire diameter
Wire diameter is responsible for current density of the elec-
trode. The ratio of current to area of cross section of electrode is
known as current density. Current density is reciprocal of square
of diameter of the electrode. If wire diameter is very less or very
large then there is a strong possibility of unbalanced depth of pen-
etration. So diameter of electrode should be selected properly.
Fig. 2.1. Welding with Submerged Arc Welding Setup.
Please cite this article as: H. Sharma, B. Rajput and R. P. Singh, A review paper on effect of input welding process parameters on structure and properties of
weld in submerged arc welding process, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.02.422
Fig. 2.2. Block Diagram of Submerged Arc Welding Process.
3.5. Granular flux
In shielded metal arc welding the coating on stick electrodes is
done for shielding of weld but in submerged arc welding case the
shielding of weld is achieved by using granular flux. The flux can
contain the desired material for weld which may be lost during
welding. The fluxes are of 4 types as fused, bonded, agglomerated
and mechanically mixed fluxes. To remove moisture hygroscopic
fluxes are used. Different types of halides are used to obtain high
strength weld.
3.6. Extended length
If extended length is increased the resistance of wire increases
and hence temperature is increased which indicates lower current
can be supplied. But if current is lowered the current intensity
decreases and so optimum extended length should be used.
3.7. Hopper
It is used to contain and supply the granular flux to the weld
portion in required amount utilizing the gravity principles.
4. Literature review
Austin J.B et al found that the penetration is affected by cur-
rent, voltage and travel speed. They described some other factors
also which affect the arc penetration, are thermal conductivity,
arc length and arc force. Their study revealed that if the thermal
conductivity of the work material is higher, the shallower arc pen-
etration will be the result. They described that the penetration will
be poor if the arc is too small [1].
Belton et al found that the arc penetration is affected by the
amount of SiO2 in the flux and width to depth of penetration ratio
increases with decrease in the amount of SiO2. They described that
the basicity of the flux also affects the width to depth ratio of pen-
etration [2].
Daemen et al made the conclusion that at 850 °C the changing
of ferrite to austenite phase occurs very rapidly in the alloys 316L.
Taking in consideration both the low cooling rates while the strip
welding and the fact that the ferrite pools have smaller dimensions
in a weld metal than in casted /forged steels, it is possible to clarify
the presence of sigma phase in the deposit weld metal. In the case
to avoid this type of transformation which is predetermined for the
corrosion resistance of the alloys, the welding consumables should
be specially designed. The mixture r-c found to be very sensitive
to corrosion which is formed in the original site of ferrite. All the
etchants are seemed to generate considerable corrosion effects
on those areas. On observing the results obtained, they concluded
 H. Sharma et al. / Materials Today: Proceedings xxx (xxxx) xxx
that the low ferrite alloys like r 316L have higher corrosion rates
[3].
Renwick et al worked on different characteristics on varying
the different parameters and found that the weld bead penetration
and melting rate increases with the increase in the welding cur-
rent. Renwick also found that the higher the welding the flatter
and wider would be the weld bead and the flux consumption
increases with the increase in welding voltage [4].
Bailey N et al stated that the influence of compositional factors
on the cracking during solidification in submerged arc welding can
be directly estimated by trans-varestraint test. They explained that
the composition based crack susceptibility values and the cracking
of original welds in C and C-Mn based steels made with a variety of
weld compositions can be significantly correlated. They told that
the test cannot determine the influence of factors which alter the
weld shape since such variations alter the test conditions. This pos-
tulate has certain limitations, which are accepted, modifications
can be carried out to compare trans-varestraint results obtained
from these tests giving various weld shapes. They suggested cer-
tain measures which are recommended to minimize cracking in
solidification, these measures are, techniques of gap filling, use of
filler metals with low carbon content, Sulphur and Phosphorous
constituents and the application of proper power techniques to
enhance the deposition by increasing or maintaining deposition
rate while preventing the predetermined effects of large dilutions
and large depth to width ratios [5].
Dallam et al studied the effect of flux composition on different
parameters like microstructure of the submerged arc weldment
and toughness of the weldment. They attempted to study the
chemical and crystalline nature of the particles and used the acid
dissolution techniques [6].
Grong et al studied the weldment in mild and HSLA steels dur-
ing SAW processes and presented a significant review on the clas-
sification of the weld micro-structures that are produced in mild
steel and HSLA steels during SAW processes. They found that the
finally developed micro-structure of weld would depend on the
cooling rate from 800 to 500 °C (D T 8/5), mostly on austenite grain
size, distribution of non-metallic constituents and chemical com-
position of the weld. The factor, D T 8/5 is considered to be an
effective representation of the amount of austenite to ferrite trans-
formation in HSLA steel welds [7].
Gowrisankar et al revealed that the minimum delta-ferrite
content in the root region of the weld increases with the increase
in the number of passes during welding, and also the difference
between the delta ferrite contents at the surface and root of the
weld decreases with increase in number of passes. They also found
that the hardness and tensile strength properties increase with
increase in number of passes during welding while decrease in
ductility and impact properties [8].
R. S. Chandel et al found that the melting rate is affected by the
current, arc voltage, wire diameter, electrode extension (EE), elec-
trode polarity, power source and flux classification for the sub-
merged arc welding process. They explained that for a given wire
diameter, electrode polarity and electrode extension if we increase
the welding current it will give rise in the melting rate. They fur-
ther explained that higher melting rates are obtained when larger
electrode extension, negative electrode and smaller diameter elec-
trodes are used for the same welding current and melting rate is
not significantly affected by the arc voltage and type of power
source used [9].
McGrath J T et al evaluated the mechanical properties like
strength, notch toughness and the related microstructure for a ser-
ies of welds deposited in thick section of steel using the submerged
arc narrow-groove process. They found that all weld metals depos-
ited with a range of wire chemistries (variations in Mn, Si, Mo con-
tents) and flux basicity, achieved the targeted tensile properties of
Please cite this article as: H. Sharma, B. Rajput and R. P. Singh, A review paper on effect of input welding process parameters on structure and properties of
weld in submerged arc welding process, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.02.422
3
275-MPa yield and 482-MPa ultimate tensile strength. They told
that the welds that did not achieve the required low-
temperature notch toughness properties contained a coarse-grain
boundary ferrite and ferrite with second phase microstructure
[10].
V. R. Mattes et al found that if alloying additions and thermo
mechanical processing are carried out on high strength low-alloy
(HSLA) steels then these have good metallurgical changes and lead
to improved combinations of engineering material properties by
the micro-structural control. They explained that the physical met-
allurgy principles which are employed in HSLA steels include addi-
tion of morphology, carbon nitride solubility, refinement of grains,
precipitation hardening and strengthening of substructures. They
also found that the addition of small amounts of elements such
as niobium, titanium or vanadium leads to the differences in struc-
ture and properties. From all, this is the secret behind success of
HSLA steel in the micro alloying [11].
Joarder A. et al studied the influence of various welding param-
eters which are responsible for the chemistry of welded metal.
They found that the operating parameters significantly affect the
weld deposition chemistry. They further found that the mechanical
properties of the weld metal that are developed during welding are
mainly determined by micro-structure [12].
Yang et al studied the effect of the welding current on the
width of weld bead and found that if the welding current is
increased then the width of weld bead increases for the given elec-
trode diameter and electrode extension then it reaches a maximum
value of width after that it decreases for further increase in the
value of welding current [13].
Gupta et al studied the effect of flux and various welding
parameters on submerged arc welding process. They used five
different-different welding fluxes in their study of submerged
arc welding process using mild steel and found that the depth
of penetration and width of the weld bead are significantly
affected by the basicity of flux and different welding parameters.
They found that the flux basicity does not appreciably affect the
reinforcement but it is affected by welding parameters. They also
found that at lower welding current range, the width of heat
affected zone (HAZ) is lower with higher value of basicity of flux
in comparison to lower values of basicity. They could not find any
specific trend of the variation of width of HAZ with the basicity of
the flux by keeping the other welding parameters at constant val-
ues [14].
Murugan et al studied the weld bead of submerged arc welding
process and explained the effect of welding voltage, welding speed,
electrode extension, and wire feed rate on the weld bead dimen-
sions of plate of steel IS 2062 having 20 mm thickness. They found
that if the welding speed is decreased then the weld width, pene-
tration and reinforcement height increase. They also found that
these parameters increases with the increase in the wire feed rate.
They found that with increase in the electrode extension weld
width increases but the depth of penetration decreases [15].
Murugan et al investigated and found that if the high voltage
and high welding speed are employed together in submerged arc
welding then low dilution in the weld is the result. They wrote that
the low dilution conditions are beneficial in surface cladding as this
leads to good ductility and resistance to inter granular corrosion in
the cladding material [16].
Chandel et al has studied and analyzed the behavior of differ-
ent welding parameters and developed software for the predic-
tions of the effect of welding current, polarity of electrode,
diameter of electrode, and electrode extension mainly on melting
rate, height of weld bead, width of weld bead, and penetration of
welding in submerged arc welding. The software is fully based
on the algorithms that were developed by Yang et al. for the eval-
uation of the weld bead geometry. The limitation of this software is
4 H. Sharma et al. / Materials Today: Proceedings xxx (xxxx) xxx
that this software predicts the weld bead geometry for the bead-
on-plate (BOP) type of welds [17].
Gunaraj et al studied the submerged arc welding for pipes for
two configurations of pipe weldings namely bead-on plate(BOP)
and bead-on joint(BOJ). They investigated the effect of controllable
process variables on the heat input and the area of the heat-
affected zone (HAZ) by using the mathematical models developed
for the submerged arc welding of pipes [18].
Aksoy M et al studied the weld and established a relationship
between initial grain size, micro-structure, hardness of the weld
metal, and toughness of weld metal and heat affected zone
(HAZ). They concluded from the results that there is major effect
of initial grain size on the hardness of the weld, micro-structure
of the weld, toughness of the weld metal and HAZ of low carbon
steel by taking the heat input constant [19].
Lee et al found that if the welding current increases the heat
affected zone (HAZ) to weld bead size ratio decreases. They inves-
tigated that individually the heat affected zone size and weld bead
size increases with the increase in the welding current. They also
compared the variation in the HAZ size and weld bead size with
the increase in the welding current and found that the weld bead
size increases in a greater amount in comparison to the size of
the heat affected zone (HAZ) [20].
Viano et al studied and investigated the weld in two-wire tan-
dem submerged arc welding of HSLA steel. They described the
effect of overall heat input in the welding and the effect of welding
speed on the micro-structure of the weld, mechanical properties of
the weld and the weld profile. They found that for all heat inputs,
increase in the welding speed produces weld profile free of under-
cuts and the average inclusion size increases with the increase in
the heat input but the density of the inclusion decreases with the
increase in heat input. They found that acicular ferrite volume frac-
tion, hardness and the charpy impact toughness of the weld
decreases with increase in overall heat input of the weld for a given
welding speed [21].
Vera et al studied the submerged arc welded pressure vessel of
steel and investigated the effect of Postweld heat treatment
(PWHT) on the mechanical properties and micro-structure of the
heat-affected zone (HAZ), base metal and weld metal of the sub-
merged arc welded pressure vessel. They used the ASTM A537 C1
steel. From the study they reached to the conclusions that the ten-
sile and impact properties of base metal decrease slightly but the
impact strength of welded metal increases [22].
Gunaraj et al studied the submerged arc welding process for
the welding of pipes and developed mathematical models for the
optimization of the results that were obtained in the form of weld
bead quality. They developed Response Surface Methodology
(RSM) for investigation and optimization of the quality of weld
bead in submerged arc welding of pipes by the utilization of math-
ematical models that were developed by them [23].
Jun, H. J. et al studied the micro-structure of the welding joint
and found that it is very critical task to recognize the micro-
structure of the weld zone. They wrote that the micro-structure
is investigated in order to forecast the toughness and strength of
the welded joint and the steels which are used for joints have
micro-structure with fine grains and useful required properties.
They told that the joint can fail due to lack of toughness after weld-
ing because of micro-structural changes in heat affected zone
(HAZ). They further described that the coarse-grained heat affected
zone has higher toughness in comparison to the fine-grained HAZ
[24].
Jerzy et al studied the welding joint and the effect of parame-
ters of welding on the weld thus produced. They focussed on the
effect of the overall heat input on the weld of submerged arc weld-
ing (SAW) process. They selected duplex steel UNS S31803 for their
study and investigation. As the result of their investigation and
Please cite this article as: H. Sharma, B. Rajput and R. P. Singh, A review paper on effect of input welding process parameters on structure and properties of
weld in submerged arc welding process, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.02.422
test, they found that the weld defectiveness of duplex steel
increases with the increase in the plate thickness of the weld. They
found that the occurrence of inadmissible welding imperfections in
joints reduces with the increase in the heat input during the weld-
ing, which ultimately reduces the costs of testing of the quality of
weld and thus reduce the cost [25].
Ana et al studied the fluxes that are used in the submerged arc
welding and characterized the fluxes of submerged arc welding on
the basis of their structure, characteristics and chemical composi-
tions. This characterization enabled one to quantify the ions and
free electrons which might be present there in the plasma arc
formed in submerged arc welding due to the presence of flux. Their
study and analysis helps one in prediction and determination of
the reactions which are taking place in the weld pool. They con-
cluded that the selection of the flux has more importance [26].
P. Kanjilal el at studied the different flux composition with
respect of different welding parameters. Their study and investi-
gation leads to the development of a rotatable design based
upon statistical analysis for mixture of fluxes to forecast the
mixed effect of mixture of flux and parameters of welding. They
carried out the experiments for bead-on-plate welds deposited
on low carbon steel plates applying the combination of different
welding parameters and different flux compositions .The results
obtained from the study shows that the variables related to flux
mixture based on ingredients of the flux and parameters of the
welding have separate as well as combined effects on the results
like weld material chemical composition and mechanical proper-
ties of the weld [27].
Datta et al studied and analyzed the weld bead and the sub-
merged arc welded metals. From the results and predictions they
developed a type of statistical model for predetermining and fore-
casting the volume of the weld bead produced in submerged arc
butt-welds [28].
Keshav Prasad et. At studied plain carbon steel weld joint.
Keshav revealed the influence of the submerged arc welding on
the microstructure and hardness of the weld in submerged arc weld-
ing .He used heat input as the process parameter of his study .in his
study and investigation author used a 16 mm thick plate of plain car-
bon steel and then after welding by submerged arc welding process ,
he analyzed it .he found that the peak hardness in the welded metal
was found in the heat affected zone(HAZ) and the hardness varies
from weld centreline to the base metal .if we increase the heat input
in the SAW welding this leads to coarsen the grain structure in the
weld metal .at the given welding speed if we increase the welding
current than the toughness of the weld .[29]
Biswas et al. has studied and analyzed the weld in the sub-
merged arc welding process .he also investigated the effect of var-
ious process parameters of submerged arc welding on the output
features of the weld thus obtained .these influences of different
process parameters on the output features of submerged arc weld
are determined by using Taguchi method .so Biswas used Taguchi
method to predict the effect of process parameters on the weld in
submerged arc welding.[30]
5. Conclusion
On going through the investigations done by the selected
researchers some conclusions can be derived for input–output pro-
cess parameters for the structure and properties of the weld
obtained through submerged arc welding process. These can be
summarized as below:
1. The mechanical properties of the weld have strong relation with
the macro and microstructure of the weld obtained by sub-
merged arc welding process.
 H. Sharma et al. / Materials Today: Proceedings xxx (xxxx) xxx
2. Submerged arc welding process is used to produce high quality
welds having ferrite content more than 4%.
3. If number of passes of weld is more, then complete transforma-
tion of delta ferrite to austenite is not possible due to the exis-
tence of differential heating and cooling rates in passes. This
develops superior quality of weld having more tensile strength
and hardness.
4. If arc voltage or welding current is increased the hardness
increases but tensile and impact strength values decrease.
5. If voltage is increased the weld width increases.
6. The microstructures of weld zone and heat affected zone are
entirely different.
7. Manganese, Silicon Sulphur etc is alloyed to increase some
specific properties of the weld.
6. Scope for further work
1. Little work is reported on metal transfer influencing chemical
composition, bead geometry, strength and metallurgy of weld
in submerged arc welding process.
2. Transient study of current voltage in submerged arc welding
requires more work, as it is the least searched area.
3. The optimum values of input output welding variables are not
searched yet, it should be tried by utilizing MAT Lab and ANN
etc to simulate properly.
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weld in submerged arc welding process, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.02.422
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