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SAW Welding Process
SAW Welding Process
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Lecture 3 P1
SAW: Process Fundamentals (
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--- ------
------------
p2
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NELD
3ACKING
'lATE
-----------------------
Lecture 3 p:
SAW Weld Pool (
Electrode
> ,¥Grariular
" , Flux
Arc Cavity
l_ ..... _._-----
re 3 p4
SAW Electrodes
Lecture 3 p~
SAW Fluxes (
• Flux constituents
- The flux consists of granular minerals and metals in the
form of fused and crushed or bonded agglomerated
particles
e3 p6
SAW Flux Types for Steels
• Various formulations in use
• Calcium silicate
• Manganese silicate
• Aluminate rutile or basic
• Basic fluorides
• Fluxes termed "neutral" or "active" according to
their potency in modifying weld composition
• Also categorized as "basic" or "acid" based on
various indices e.g.:
1
CaO +CaF 2 + MgO + K 2 0+Na 2 0 +4MnO + FeO)
B 0 2
Si0 2 + ..!..-(A/2 0 3 + TiO 2 + Zr0 2 )
2
Lecture 3 p7
SAW Fluxes (
--""--""-"----- - -
e3 p8
Classification of SAW Electrodes
and Fluxes for Carbon Steel
• AWS/ASME A5.17 specification
• Solid electrodes are classified on the basis of
their chemical composition
• Composite electrodes and fluxes are
classified according to the composition of the
weld metal deposited with a particular
electrode
• FXXX-EXXX designates a flux/wire
combination
- e.g., F7A6-EM12K
Lecture 3 pS
SAW Welding Procedures (
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e3 p10
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P 11
SAW Welding Procedures (
FLUX
BACKING
FLEXIBLE
SHEET
MATERIAL
mOUGH
INFLATED
HOSE
.. ~_._---~ ---
e3 p12
SAW Welding Procedures
Single-electrode two-pass welding of steel
plate
Root Pass
Lecture 3 p13
SAW Welding Procedures (
~
c=t..--------,}
=EC:-le-cC:-tr-od--:-e-~· I Lack of fusion
Iignment in Correct Incorrect
o-pass
elds II
Exception-unequal thicknesses
_.~ _ J
e3 P 14
------------- - - - - - - - -
I,
'-----~-~ ~--
Lecture 3 P 1~
--~ ~-- ~----~-~-----------------~
SAW Variants (
Twin-wire dclac system:
1-dc power source, 2-ac power source, 3-lrail are, 4-lead arc
~--~-~--------------------
-_._--------~~ - - - ~~ .. --~---------
e3 p16
~~ ----~----------- ---------------------,
SAW Variants
Strip Cladding
strip
Electrode
Power Supply
Welding
Direction
Lecture 3 pH
SAW Equipment (
• Power Supply
- Constant current or constant voltage type 100% duty cycle
1000 A output
• Wire Feeder
- Constant speed (for constant voltage power supplies) or
voltage sensing (for constant current power supplies)
e3 p16
-- - ---- ---------------------
SAW Applications
Lecture 3 p1E
SAW Applications (
• Surfacing
- multi-wire & strip cladding variants
- - - - - - - - - - - - - - - - - _. . _. __ . __. _ - - - - - - -
e3 P 20
- ~ .. _----~--- -~~~~- -~~~~~--~~~
Lecture 3 P 21
(
Welding Processes
Electro-Slag Welding
(ESW)
----,-
3 P 22
~---'-- -
ESW Process Fundamentals
Lecture 3
ESW: Process Fundamentals (
ELECTRODE GUIDE
TUBE
MOLTEN WELD ELECTRODE
POOL
J..-~- WATER-COOLED
SHOE
COMPLETED WELD
WELD DIRECTION . /
WORKPIECE
ce 3 p24
r--ESW Consumable Guide Method
POWER SOURCE CONTROL
PANEL
ELECTRODE
WIRE FEEDER
/
WORKPIECE
Lecture 3 P 2~
ESW Welding Procedures (
• Process Variables
- Joint Preparation & Fit-up
- Welding Current
- Welding Voltage
- Electrode Extension
- "Form Factor"
- Electrode Oscillation
- No of Electrodes & Spacing
e3 p26
ESW: Joint Types
--- ...
Bull Joint Comer Joint T-Joint
--- ..
'-
-
Cross Joint Overlay Buildup
Lecture 3 P 27.
ESW: Joint Fit Up and Alignment (
Run-off TabS~:r;~rJ::;'
Temporary Strongbacks
Welded to Plate
40 mm min.
Starting Sump
I Root Opening
03 P 28
ESW Welding Procedures
Lecture 3 p29
ESW: Weld Metal Grain Structure (
A
L Plate -
Thickness
Transverse Section
Solidification Welding
Front Direction
e3 P 30
ESW: Weld Grain Structure
Solidification
Front
Lecture 3 P 31
ESW: Weld Faults (
[lJ
crackl~g
:::-
)~k
(f) Incomplete
Fusion
e3 P 32
ESW: Production Rates
mm
o 100 200 300 400
...
=E 60 1500
-w
c
C
2 Electrodes
W 3 Electrodes 1000
Q.
(I)
40 ...
~E
C)
z:
-920 500
~ 1 Electro e
IRoot O~!!!9 29 mm I
lL-J.......J.-.L-I-~~~~~~O
2 4 6 8 10 12 14 16
PlATE THICKN~SS (in)
Lecture 3 P 33
ESW Applications (
e3 P 34
ESW Capabilities and Limitations
Lecture 3 P 3~
(
Welding Processes
33 P 36
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EGW Process Fundamentals
Lecture 3 p37
EGW Process Fundamentals (
___-~~.Drive Rolls
Electrode
WELDING • Conduit
DIRECTION ~~ t
Gas <;'¥"
h,!i:
~~~fJl:" _ ......._ ;
~~;;~;;
ELECTRODE = .- Primety
Shielding Gas
_ Supplementary
Shielding Gas
Water
FIXed Shoe
SOLIDIFIED
WELD METAL
03 P 38
EGW Welding Procedures
• Operating Variables
- Materials and consumables
- Joint fit-up and alignment
- Welding Voltage
- Welding Current/Electrode Feed Speed
- Electrode Extension
- Electrode Oscillation
Lecture 3 P 3'
EGW Consurnables
(
L ~
e3 P 40
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Classification of EGW Consumables
• AWS A5.26 Specification for Consumables Used for
Electrogas Welding of Carbon and High Strength Low Alloy
Steels
, - - - - - - - - - • Denotes an EGWelectrode
- - - - - - - - . Indicates the min. weld metal strength in
10 ksi
i ,------- . Indicates the minimum impac1 strength
1 • Designates a flux-cored electrode (The
EG X X T X X X letter S designates a solid elec1rode
Lecture 3 P 41
-~~--~-----------------------,
{J L----'< f"Ca~~
22mm
r---=i I- 4mm
<--I \ l-- ?
s~;..;»
---I
22mm
Moving ShOD
e3 p42
EGW Welding Procedures
Lecture 3 p43
EGW Equipment c
• Power supply
• Electrode feeder
• Electrode guide
• Electrode guide travel and oscillator
• Retaining shoes
• Controls
ra 3 P 44
EGW: Applications
~~~~~~~-
The principal
applications of EGW
include storage tanks,
pressure vessels,
structural members
and ship hulls.
Lecture 3 p45
EGW Capabilities and Limitations (
e3 P 46