Acoustics India Private Limited

VALVE
WELDING IN SAW PROCESS

By
B.RAKHAVENDRAN
OBJECTIVE b
o

1.) To Provide Theoretical and Practical Training to the Welders.

2.) To improve procutivity and quality of welding.

3.) To discuss about the types of flux used for different materials.

4.) To discuss about the selection of coil based on the thickness of job.

5.) Safety work practises.

Points to Discuss:

1.) Introduction to SAW (Submerged Arc Welding). .

2.) Process of Submerged Arc Welding.

3.) Features.

4.) Theoretical & General operating conditions.

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SAW - SUBMERGED ARC WELDING
1.) Submerged Arc Welding (SAW) is a common welding process that is
commonly used in the structural and vessel construction industries.
2.) It is commonly used in beam, boom, tractor, and multi-head type rigs.
3.) The electrode is constantly fed into the arc and as it is melted, a layer of
granular flux provides a protective cover beneath which the welding occurs.
4.) The blanket is created as some of the flux becomes molten.
5.) The remainder of the flux is recovered and reused, unless it has become
contaminated.
6.) In the automatic version of SAW, the process is performed with a set of rollers
driven by a controlled motor to ensure that the wire is fed into the arc at a speed
rate that is equivalent to the rate at which the electrode is melted.
7.) The arc length remains constant as a result. The SAW process is usually
automated. however, there are semi-automated systems available, too.

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Variables of the SAW Process

1) The arc voltage

2) The wire feed speed

3) Travel speed

4) Contact tip to work (CTTW) or electrode stick-out (ESO)

5) Polarity and current type

SUBMERGED ARC WELDING ( VALVE)

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PROCESS OF SUBERGED ARC WELDING (SAW)

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FEATURES

FLUX HOPPER
• It stores the flux and control the rate of flux deposition on the
welding joint

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WELDING HEAD
• It feeds flux and filler metal to the welding joint .Electrode
(filler metal ) gets energized here

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FLUX
FLUX

1.) In addition to providing a protective cover over the weld, the flux
shields and cleans the molten puddle.

2.) The flux also affects the chemical composition of the weld metal, the
weld bead shape, and the mechanical properties of the weld.

3.) Another function of granular flux is to act as a barrier that holds the heat in
and concentrates the heat into the weld area to promote deep penetration.
FLUX

• The granulated flux shields and thus protects molten weld from
atmospheric contamination the flux cleans weld metal.

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 GENERAL OPERATING CONDIATIONS

• CURRENT :The total welding current can range between 450 - 550 Amps

• FLUX USED : ESAB,ADOR

• FILLER WIRE : EL8 F7PZ & EM12K F7AZ (Ø 4 mm )

• VOLTAGE : 23 - 30 Volt

• TRAVEL SPEED : 110 - 326 mm/min

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 SELECTION OF FILLER WIRE BASED ON
MATERIALS FOR SAW
ADDITIONAL
MATERIAL COIL FULX
REQUIRMENTS
EL8 F7PZ (post weld) Ador
SA 10S,SA106 GrB NO
IS 2062/SA516 Gr 70 F7AZ (after weld) Ado
r
F7PZ (ESAB)
SA516 Gr 70 (C S) EM12 K F7AZ (ESAB) NO

SA105,SA106 Gr B EM12K F7P2,F7P4 (Ador) IMPACT Requirment

SA516 Gr 70 (C S) EH14 F7P5 (ESAB) -yes
SS 3.4 ER308
AUTOMELTD S-33 NO
SS 316 ER316
IMPACT Requirment
F8P0 (ESAB)
ALLOY Gr22 (A S) EB3-B3 -yes
F8PZ (ESAB)
NO
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WELDING OF FACE PLATE WITH SIDE PLATE WELD

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FACE PLATE TO SIDE PLATE WELD AFTER
WELDING

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FACE PLATE WITH FLANGE WELD
fa

DURING WELDING AFTER WELDING

ADVANTAGES OF SAW PROCESS

• High Quality.

• Little risk of undercut and porosity .

• No spatter.

• Higer desposition rate.

• High welding speed are possible.

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THANK YOU