SUBMERGED ARC

WELDING CONSUMABLES
FILLER WIRE
•IRECT CURRENT ELECTRODE POSITIVE
• SOLID WIRE
• METAL CORED WIRES
• STRIPS
• METAL POWDER
CURRENT RANGE FOR
SOLID WIRES
Wire diameter Current range
(mm) (amps)
1.6 150 - 300
2.0 200 - 400
2.4 250 - 500
3.15 300 - 600
4.0 450 - 750
5.0 600 - 1000
6.3 700 - 1200
 ELECTRODE SIZES AND
TOLERANCES

TOLERANCE (mm)

DIAMETER SOLID (E) COMPOSITE

(EC), mm

1.6 TO 2.8 + - 0.04 + 0.04, - 0.05

______________________________________________

3 TO 6.4 + - 0.06 + 0.06, - 0.08

______________________________________________
 FUNCTIONS OF
COPPER COATING

• TO PREVENT RUSTING OF WIRE

• ENABLE EASY CURRENT TRANSFER

• REUCE FRICTION IN WIRE GUIDES

FLUX CONSTITUENTS
(TYPICAL)
CaO TiO2
MnO ZrO2
K2O Al2O3
NaO FeO
SiO2 CaF2
 FUNCTIONS OF FLUX

• PROVIDE SHIELDING

• CONTROLWELDMETALCHEMISTRY

• SCAVENGING OF IMPURITIES
 SCAVENGING ACTION
SULPHUR

[FeS]+(Mn) (MnS)+[Fe]

[FeS]+(Mno) (MnS)+[FeO]

[FeS,MnS]+(CaO) [FeO,MnO]+(CaS)
SCAVENGING ACTION
PHOSPHOROUS

[2P]+(5FeO) (P2O5)+[5Fe]

(P2O5)+(4CaO) (Ca4P2O3)
FUNCTIONS OF FLUX

• ARC STABILITY
• GOOD MECHANICAL
PROPERTIES

• SELF PEELING SLAG

 FUNCTIONS OF SLAG

• REDUCE COOLING RATE

• PROVIDESECONDARY SHIELDING
• CONTROL BEAD GEOMETRY
• CRUSHED SLAG AS A SHIELDING
MEDIUM (SELECTED APPLICATIONS)
PROPERTIES OF FLUXES

PROPERTIES AT R T

• BULK DENSITY

• PARTICLE SIZE

• FLOWABILITY
PROPERTIES OF FLUXES
PROPERTIES AT ELEVATED
TEMPERATURE
• MELTING RANGE
• SURFACE TENSION
• VISCOSITY
• ELECTRICAL CONDUCTIVITY
PROPERTIES ON COOLING
• THERMAL CONTRACTION
WELDING CHARACTERISTICS

ARC STABILITY

ABILITY TO GIVE ACCEPTABLE

WELD BEAD SHAPE

WELDING SPEED RANGE

SLAG DETACHABILITY
 WELDING CHARACTERISTICS

• MOISTURE CONTENT AND

HIGROSCOPICITY

• METAL TRANSFER

• EFFECT ON ELEMENT TRANSFER

• FLUX CONSUMPTION
TYPES OF FLUXES

• FUSED

• BONDED

• AGGLOMERATED
CHARACTERISTICS
OF FLUXES
FUSED
• Crystalline
• Homogenous
• Non hygroscopic
• Sharp edges
CHARACTERISTICS
OF FLUXES
AGGLOMERATED
• Mixture
• Non Homogenous
• Hygroscopic
• Globules
FLUX RECYCLING

• FUSED
UNLIMITED
• AGGLOMERATED
LIMITED
 FLUX DRYING

• FUSED
150 C For1 Hr
• AGGLOMERATED
300 C For 2 Hr
CLASSIFICATION OF
FLUXES

• ACIDIC
• NEUTRAL
• BASIC
 BASICITY INDEX
It is weight coefficient describing the different affinities of
various basic oxides to SiO2.

TYPICAL EXPRESSION FOR BASICITY INDEX

%CaO+%CaF2 + %MgO+%K2O

+%Na2O+1/2(%MnO+%FeO)
B1 = --------------------------------------------------

%SiO2 + ½(%Al2O3 +%TiO2+ %ZrO2)

FLUX CLASSIFICATION

BASICITY CLASSIFICATION
INDEX

<1 Acidic flux

1 to 1.5 Neutral flux

> 1.5 Basic flux

AWS CLASSIFICATION
CARBON STEEL
AWS 5.17

ALLOY STEEL
AWS 5.23
 AWS CLASIFICATION
Flux - Wire combination
Alloy steel

FS XX X X– EC XXX X–XX XH X
F – Flux E – Electrode H - Hydrogen

S – Slag C – Cored wire X – H content

X – Min Ten Strength X – Weld metal composition

X – Heat treatment X – Test temperature

X – N Nuclear / R Reduced residual requirements

X – Wire composition
 AWS CLASIFICATION
Flux - Wire combination
Carbon steel

FS XXX – ECXXX–HX
F – Flux E – Electrode H - Hydrogen

S – Slag C – Cored wire X – H content

X – Min Ten Strength X – Mn Content

X – Heat treatment X – Carbon content

X – Test temperature X – Condition of core wire

IMPACT TEST REQUIREMENTS
Digit Maximum Test Minimum Average
Temperature oC Energy Level

0 0
2 -20 27 Joules
3 -30
4 -40
5 -50
6 -60
Z No Impact requirements
 DIFFUSIBLE HYDROGEN
REQUIREMENTS
Diffusible Hydrogen Average Diffusible
Designator Hydrogen
(maximum ml/100gr)

H16 16.0
H8 8.0
H4 4.0
H2 2.0
 EXAMPLE

CARBON STEEL

F 48 A2 – E M12K
 EXAMPLE

ALLOY STEEL

F 62 P2 – E B3N – B3N

F 70 A2 – E B2 R – B2 R
 IIW CLASSIFICATION OF
FLUXES
_________________________________________________________
SYMBOL Principal Compounds Common Name

CS CaO+MgO+SiO2>50% Calcium silicate

MS MnO+SiO2>50% Manganese Silicate
AR Al2O3+TiO2>45% Aluminate Rutile
AB Al2O3+CaO+MgO>45% Aluminate Basic

BF CaO+MgO+MnO+CaF2 Basic fluoride

>50%
CHARACERSTICS OF FLUXES

Type Calcium Silicate

Description Strongly acid,

Bonded type

Characteristics Tolerates high current,

Easy slag removal

Disadvantage High oxygen pick up

CHARACERSTICS OF FLUXES
Type Manganese Silicate

Description Weakly acid,

Bonded type

Characteristics Use for fast weld,

travel speed

Disadvantage Requires relatively

clean steel
 CHARACERSTICS OF FLUXES
Type Aluminate rutile
Description Neutral aluminate
basic, Bonded type
Characteristics Can be used on steel
with rust, or mill
scale if formulated
active
Disadvantage Use only with
DC power
CHARACERSTICS OF FLUXES

Type Calcium Silicate Neutral

Description Neutral, Fused type

Characteristics Helps gain good weld

metal toughness

Disadvantage Slag removal more

difficult
CHARACERSTICS OF FLUXES

Type Basic fluoride

Description Agglomerated type

Characteristics Helps to gain good

weld metal toughness

Disadvantage Slag removal more

difficult