WELDING

Welding is an industrial art of joining metals

Welding is a process of metal joining

by applying heat and some times
pressure
 Classification of welding processes
welding

Forge or Pressure Fusion or non pressure

Welding welding
( Under pressure without ( With additional filler
additional filler metal ) metal )

Forge or Pressure welding :- The work piece are heated to plastic state & then work
pieces are joined together by applying pressure on them. In this case no filler material
is used.

Fusion or non- pressure welding :- Here edge of work piece to be joined & filler materia
both are heated to a temp. above the melting point of the metal & then allow to solidify
 Forge or pressure
welding

Welding heat created by

Furnace Electric current friction

Forge or furnace welding Resistance welding friction welding

Spot seam projection flash butt

 Fusion or non
pressure welding

Welding heat created by

gas Electric Arc chemical reaction

Oxy-acetylene welding Thermit welding

Consumable electrode Non Consumable electrode

plasma arc Carbon arc TIG

Shielded metal arc atomic hydrogen submerged arc

MIG electro slag Flux cored

 Other processes of welding are :

Solid State welding : The solid state welding depends upon the theory
that if two perfectly clean metallic surfaces are placed in an intimate contact ,
the cohesive force between atoms of the two surfaces is sufficient to hold them together.
The various solid state welding process are:
Friction Welding
Ultrasonic Welding
Diffusion Welding
Explosive Welding

Modern Welding Processes: Electron Beam Welding

Laser Beam Welding
 SAW
Submerged
Arc Welding
 Introduction
⮚ Submerged arc welding (SAW) is a method in which the
heat required to fuse the metal is generated by an arc formed
by an electric current passing between the electrode and the
workpiece.

⮚ There is no visible arc and no sparks, spatter or fume. The

electrode may be a solid or cored wire or a strip.

⮚ SAW is normally a mechanised process.

 GENERAL SCOPE

⮚ Current: the total welding current can range

between 100 and 3600 amps.

⮚Wires in one molten pool: from 1 to 6.

⮚Voltage: 20-50 volts.

⮚Speed: 30-350 cm/min.

⮚Deposition rate: 2-100 kg/hr.

 EQUIPMENTS
Hopper

Flux Power Source

Wire +
+ –
Slag
Flux Wel
••••••••••••• • Base Metal
d Arc
•
••••
SAW
PROCESS PARAMETERS

⮚ Current
⮚ Voltage
⮚ Travel speed
⮚ Size of electrode
⮚ Stick-out
⮚ Heat input rate
 Effect of current

Bead
width Penetration

Current Current

400 A 550 A 700 A 900 A

 Effect of Voltage

Bead
Penetration
width

Voltage Voltage

28 V 34 V 38 V 42 V
Influence of Amperage and Voltage

Higher amperage gives deeper penetration

Higher voltage gives wider penetration. The arc

length gets extended
 Effect of welding speed

Bead
width Penetration

Welding Welding
speed speed
 Effect of stick out

40 50 30

Ø 4 mm ; 650 A ; 32 V ; 550 mm / min

 Influence of stick-out
Longer stick-out gives higher deposition rate, but also
more shallow penetration.

Above: Penetration at different stick-out

Right: Deposition rate at different stick-outs.
A: 25 mm
B: 57 mm
C: 83 mm
 Effect of polarity

+ ~ -

DC + AC DC -
Influence of polarity and wire diameter
Deepest penetration with positive electrode. Normally, the
welding machine is equipped with DC positive electrode.

At constant amperage, the penetration gets deeper with

smaller wire diameter, due to the higher current density.
 Typical Welding
Parameter
Sr Voltage Speed Dep. Rate
Current A
no W
Ø mm V mm/min Per Arc Hr
ire
1 1.6 200-300 22-26 750-1500 3 – 4 kgs
2 2 250-350 24-26 750-1250 3- 4.5 kgs
4 2.5 300-350 25-27 750-1250 4 –4.5 kgs
5 3 400-500 28-30 500-750 5 – 5.5 kgs
6 4 550-650 30-32 400-750 5.5 - 7 kgs
7 5 600-800 30-34 350-750 6 - 8 kgs
 SUBMERGED ARC WELDING
CONSUMABLES

FILLER MATERIALS SAW FLUXES

Wire / Solid electrodes

Fused fluxes

Cored wires
Agglomerated fluxes

Strip electrodes

Metal powders
 Types Of Flux
• Fused Flux

• Agglomerated Flux
» Neutral Flux
» Active Flux
» Alloy Flux
 Neutral , Active And
Alloy Fluxes
❖ Neutral fluxes :
These fluxes do not produce any significant
change in the weld metal chemical composition due
to a large change in arc voltage or arc length /
stick out.
❖ Active fluxes :
These contain manganese and / or silicon
bearing ingredients as de-oxidiser and changes the
weld metal chemical composition with change in
arc voltage / stick out.
❖ Alloy fluxes :
contain alloying ingredients in the flux and
when used with non –alloyed carbon steel
electrode give alloy weld metal.
 Basicity Index ( B.I )
■ B.I = BASIC OXIDES / ACIDIC OXIDES =

■ [CaO+MgO+Na2O+CaF2+1/2(MnO+FeO)]
■ ----------------------------------------------------------------
■ [SiO2+1/2 (Al2O3+TiO2+ZrO2)]

■ B.I < 0.9 , ACIDIC

B.I = 0.9 to 1.2 , NEUTRAL
B.I > 1.2 -2.0 , BASIC
B.I > 2.0 , HIGH BASIC
 Function Of Flux In
SAW
• Stabilizes Arc
• Cleans the weld from unwanted impurities
• Increases Fluidity of molten metal
• Forms slag after melting & covers weld
• Allows deposited metal to cool slowly
• Compensates alloying elements Within the weld
• Eliminates spatter generation
• Helps in even & uniform bead finish
 Why Baking
Flux?
• To remove the moisture (H2O)

• To avoid possible cracking of weld due

to H2
 Baking Requirements For
Flux
• Spread the loose Flux in a Tray Of baking Oven
• Identify The Tray With The Quality/Grade Of Flux
• Bake Tray in an Oven Between 300° C to 350° C
• Baking Time 2 Hrs to 3 Hrs
• Reduce the temperature to Min 100 ° C
• Hold the Flux at this temperature till use
TYPES OF SAW
Single Wire
Twin Wire
Tandem
Tandem Twin
Multi wire
 Submerged Arc
Welding
Advantages
■ High deposition rates
■ No arc flash or glare
■ Minimal smoke and fumes
■ Flux and wire added separately -
extra dimension of control
■ Easily automated
■ Joints can be prepared with
narrow grooves
■ Can be used to weld carbon
steels, low alloy steels, stainless
steels, chromium-molybdenum
steels, nickel base alloys
 Submerged Arc
Welding
Limitations
■ Flux obstructs view of joint
during welding
■ Flux is subject to
contamination ⇒ porosity
■ Normally not suitable for thin
material
■ Restricted to the flat position
for grooves - flat and
horizontal for fillets
■ Slag removal required
■ Flux handling equipment
 Application of SAW
This welding method can be used for:-

⮚Fabrication of Boiler Pressure Vessel.

⮚Railroad tank cars.
⮚Structural shapes and cylinders.
⮚Circular welds.
⮚Beam Production.
⮚Ship Building.
⮚Circumferential welding in wind tower fabrication.
⮚Longitudinal pipe welding.
THANK YOU