1 The Process

Submerged arc welding (SAW), is a welding process where an arc is struck

between a continuous bare wire and the parent plate. The arc, electrode
end and molten pool are submerged in an agglomerated or fused powdered
flux, which turns into a gas and slag in its lower layers when subjected to the
heat of the arc, thus protecting the weld from contamination. The wire
electrode is fed continuously by a feed unit of motor driven rollers, which are
usually voltage-controlled to ensure an arc of constant length. The flux is fed
from a hopper fixed to the welding head, and a tube from the hopper
spreads the flux in a continuous elongated mound in front of the arc along
the line of the intended weld and of sufficient depth to submerge the arc
completely so there is no spatter, the weld is shielded from the atmosphere
and there are no ultra-violet or infra-red radiation effects (see below).
Unmelted flux is reclaimed for use. The use of powdered flux restricts the
process to the flat and horizontal-vertical welding positions.

Submerged arc welding is noted for its ability to employ high weld currents
owing to the properties and functions of the flux. Such currents give deep
penetration and high deposition rates. Generally a DC electrode positive
polarity is employed up to about 1000A because it produces deep
penetration. On some applications (ie cladding operations) DC electrode
negative is needed to reduce penetration and dilution. At higher currents or
in the case of multiple electrode systems, AC is often preferred to avoid the
problem of arc blow (when used with multiple electrode systems, DC
electrode positive is used for the lead arc and AC is used for the trail arc).
 Difficulties sometimes arise in ensuring conformity of the weld with a pre-
determined line owing to the obscuring effect of the flux. Where possible, a
guide wheel to run in the joint preparation is positioned in front of the
welding head and flux hoppers.

Submerged arc welding is widely used in the fabrication of ships, pressure

vessels, linepipe, railway carriages and anywhere where long welds are
required. It can be used to weld thicknesses from 1.5mm upwards.

Materials joined
• Welding of carbon steels.
• Welding low alloy steels (eg fine grained and creep resisting).
• Welding stainless steels.
• Welding nickel alloys.
• Cladding to base metals to improve wear and corrosion resistance.

2 Fluxes
Flux may be defined as granular mineral compounds mixed to various
formulations.

Welding characteristics (more stable arc, improved weld

appearance, easier slag removal, higher welding speeds)

Weld metal mechanical properties (YS, UTS and CVN)

amount of Mn and Si

Acid Neutral Basic Highly basic

Type of fluxes

Fused Agglomerated

The fused fluxes are produced when the constituents are dry mixed and
melted in an electric furnace and thereafter granulated by pouring the
molten mixture into water or on to an ice block. Subsequently, these
particles are crushed and screened to yield a uniform glass-like product.
Advantages of fused fluxes
• Good chemical homogeneity.
• Less hygroscopic, thus handling and storage are easier.
• Allow fines (fine powders) to be removed without changes in composition.
• They can easily be recycled through the system without significant
change in particle size or composition.

Disadvantages of fused fluxes

• Limitations in composition as some components, such as basic
carbonates would be unable to withstand the melting process.
• Difficult to add deoxidisers and ferro-alloys (due to segregation or
extremely high loss).

In case of agglomerated fluxes constituents may be bonded by mixing the

dry constituents with potassium or sodium silicate. This wet mixture is then
pelletised, dried, crushed and screened to size.

Advantages of agglomerated fluxes

• Deoxidisers and alloying elements can easily be added to the flux to
adjust the weld metal composition.
• Allow a thicker flux layer when welding.
• Can be identified by colour coding.

Disadvantages of agglomerated fluxes

• Are generally more hygroscopic (re-baking hardly practical).
• Gas may be evolved from the slag as it is melted, leading to porosity.
• There may be changes in weld metal chemical composition from the
segregation of fine particles produced by the mechanical handling of the
granulated flux.
3 Process Variables
There are several variables which when changed can have an effect on the
weld appearance and mechanical properties:

• Welding current.
• Type of flux and particle distribution.
• Arc voltage.
• Travel speed.
• Electrode size.
• Electrode extension.
• Type of electrode.
• Width and depth of the layer of flux.
• Electrode angle (leading, trailing).
• Polarity.
• Single, double or multi wire-system.

3.1 Welding current

• Increasing current increases penetration and wire melt-off rate

350A 500A 650A

Welding current effect on weld profile (2.4mm electrode diameter,

35V arc voltage and 61cm/min travel speed)

• Excessively high current produces a deep penetrating arc with a

tendency to burn-through, undercut or a high, narrow bead prone to
solidification cracking.
• Excessively low current produces an unstable arc, lack of penetration and
possibly a lack of fusion.

3.2 Arc voltage

Arc voltage adjustment varies the length of the arc between the electrode
and the molten weld metal. If the arc voltage increases, the arc length
increases and vice versa. The voltage principally determines the shape of
the weld bead cross section and its external appearance.
 25V 35V 45V

Arc voltage effect on weld profile (2.4mm electrode diameter,

500A welding current and 61cm/min travel speed)

Increasing the arc voltage with constant current and travel speed will:

• Produce a flatter and wider bead

• Increase flux consumption
• Tend to reduce porosity caused by rust or scale on steel
• Help to bridge excessive root opening when fit-up is poor
• Increase pick-up of alloying elements from the flux when they are present

Excessively high arc voltage will:

• Produce a wide bead shape that is subject to solidification cracking

• Make slag removal difficult in groove welds
• Produce a concave shaped fillet weld that may be subject to cracking
• Increase undercut along the edge(s) of fillet welds
• Over alloy the weld metal, via the flux

Reducing the arc voltage with constant current and travel speed will:

• Produce a stiffer arc which improves penetration in a deep weld groove

and resists arc blow

Excessively low arc voltage will:

• Produce a high, narrow bead

• Cause difficult slag removal along the weld toes

3.3 Travel speed

If the travel speed is increased:

• Heat input per unit length of weld is decreased

• Less filler metal is applied per unit length of weld and consequently less
excess weld metal
• Penetration decreases and thus the weld bead becomes smaller
 30.5 cm/min 61cm/min 122cm/min

Travel speed effect on weld profile (2.4mm electrode diameter,

500A welding current and 35V arc voltage)

3.4 Electrode size

Electrode size affects:

• Weld bead shape and depth of penetration at a given current: A high

current density results in a stiff arc that penetrates into the base metal.
Conversely, a lower current density in the same size electrode results in a
soft arc that is less penetrating.
• Deposition rate: At any given amperage setting, a small diameter
electrode will have a higher current density and deposition rate of molten
metal than a larger diameter electrode. However, a larger diameter
electrode can carry more current than a smaller one, so the larger
electrode can ultimately produce a higher deposition rate at higher
amperage.

3.2mm 4.0mm 5.0mm

Electrode size effect on weld profile (600A welding current,
30V arc voltage and 76cm/min travel speed)

3.5 Electrode extension

The electrode extension is the distance the continuous electrode protrudes
beyond the contact tip. At high current densities, resistance heating of the
electrode between the contact tip and the arc can be utilised to increase the
electrode melting rate (as much as 25-50%). The longer the extension, the
greater the amount of heating and the higher the melting rate (see below).
3.6 Type of electrode
An electrode with a low electrical conductivity, such as stainless steel, can
with a normal electrode extension, experience greater resistance heating.
Thus for the same size electrode and current, the melting rate of a stainless
steel electrode will be higher than that of a carbon steel electrode.

3.7 Width and depth of flux

The width and depth of the layer of granular flux influence the appearance
and soundness of the finished weld as well as the welding action. If the
granular layer is too deep, the arc is too confined and a rough weld with a
rope-like appearance is likely to result, it may also produce local flat areas
on the surface often referred to as gas flats. The gases generated during
welding cannot readily escape and the surface of the molten weld metal is
irregularly distorted. If the granular layer is too shallow, the arc will not be
entirely submerged in flux. Flashing and spattering will occur. The weld will
have a poor appearance and may show porosity.

4 Storage and Care of Consumables

Care must be given to fluxes supplied for SAW which, although they may be
dry when packaged, may be exposed to high humidity during storage. In
such cases they should be dried in accordance with the manufacturer's
recommendations before use, or porosity or cracking may result.

Ferrous wire coils supplied as continuous feeding electrodes are usually

copper-coated. This provides some corrosion resistance, ensures good
electrical contacts and helps in smooth feeding. Rust and mechanical
damage should be avoided in such products, as they interrupt smooth
feeding of the electrode. Rust will be detrimental to weld quality generally
since it is a hygroscopic (may contain or absorb moisture) material and thus
can lead to hydrogen induced cracking.

Contamination by carbon containing materials such as oil, grease, paint and

drawing lubricants is especially harmful with ferrous metals. Carbon pick-up
in the weld metal can cause a marked and usually undesirable change in
properties. Such contaminants may also result in hydrogen being absorbed
in the weld pool.

Welders should always follow the manufacturer's recommendations for

consumables storage and handling.
5 Power Sources
In arc welding it is principally the current which determines the amount of
heat generated and this controls the melting of the electrode and parent
metal and also such factors as penetration, and bead shape and size.
Voltage and arc length are also important factors with increasing voltage
leading to increasing arc length and vice-versa. Usually in SAW a constant
voltage (or flat) characteristic power source is used.

Power can be supplied from a welding generator with a flat characteristic or

a transformer/rectifier arranged to give output voltages of approximately
14-50V and ranges of current according to the output of the unit these can
be in excess of 1000A.