Electroslag Welding

Electroslag welding produces the coalescence of metals

using heat generated by passing electric current through
molten conductive slag, which melts the base and filler
metals. Although this process is most often employed to
weld metals in the vertical or near-vertical position, usually
in a single pass, it can be used at angles of 45° or greater
from vertical.

The process is initiated by an arc that heats a granulated

flux and melts it to form the slag. The arc is then
extinguished by the conductive slag, which is kept molten
by its resistance to the electric current passing between the
electrode and the workpieces
 Electroslag welding is a mechanized welding process, and once
started, it continues to completion.
 Since no arc exists, the welding action is quiet and spatter-
free.

 Extremely high metal deposition rates allow the welding of

very thick sections in one pass.

 A high-quality weld deposit results from the nature of the

melting and solidification during welding. No angular distortion
occurs in the welded plates.

 The process is initiated by starting an electric arc between the

electrode and the joint bottom.

 Granulated welding flux is then added and melted by the heat

of the arc.

 As soon as a sufficiently thick layer of molten slag (flux) is

formed, all arc action stops, and the welding current passes
from the electrode through the slag by electrical conduction.
The heat generated by the resistance of the molten slag to
passage of the welding current is sufficient to melt the welding
electrode and the edges of the workpiece.

The interior temperature of the bath is approximately 1925°C (3500°F). The

surface temperature is approximately 1650°C (3000°F).

The melted electrode and the base metals collect in a pool beneath the
molten slag bath and slowly solidify to form the weld.

Progressive solidification occurs from the bottom upward, and molten metal
is always present above the solidifying weld metal.
Nonconsumable Guide Method
of Electroslag Welding (Three
Electrodes)
Electroslag Welding Speeds
for Various Plate Thickness
The conventional method of electroslag welding can be used to weld
plates ranging in thickness from approximately 13 mm to 500 mm (1/2
in. to 20 in.).

Thicknesses from 19 mm to 460 mm (3/4 in. to 18 in.) are most

commonly welded.

One oscillating electrode can successfully weld thicknesses up to 120

mm (5 in.); two electrodes, thicknesses up to 230 mm (9 in.);

and three electrodes, thicknesses up to 500 mm (20 in.).

With each electrode, the process deposits approximately 11 kg to 20 kg

(25 lb to 45 lb) of filler metal per hour.

The diameter of the electrode used is generally 3.2 mm (1/8 in.).

The electrode metal-transfer efficiency is almost 100%.

The normally large weld produced by electroslag welding consumes

approximately 2.3 kg (5 lb) of flux for each 45 kg (100 lb) of deposited
weld metal.
Consumable Guide Method of
Electroslag Welding
 Extremely high metal deposition rates of 16 kilograms per hour (kg/h) to
20 kg/h (35 pounds per hour [lb/h] to 45 lb/h) per electrode can be
achieved;
 Very thick materials can be welded in one pass;
 Only one equipment setup is required, with no interpass cleaning, since
only one pass is involved;
 Preheating is not normally required, even on materials of high
hardenability;
 High-quality weld deposits can be made because the weld metal stays
molten for an appreciable time, allowing gases to escape and slag to float
to the top of the weld;
 Minimum joint preparation and fitup is required, as mill edges and flame-
cut square edges are normally employed;
 The process has a high duty cycle because it is mechanized and, once
started, continues to completion, causing little operator fatigue;
 A minimum of materials handling is involved, as the workpiece needs to be
positioned only to place the axis of the weld in a vertical or near vertical
position. No manipulation of the workpieces is needed once the welding
operation has started;
 Weld spatter is eliminated, which results in 100% filler metal deposition
efficiency;
 Low flux consumption; 0.45 kg (1 lb) of flux is used for each 9 kg (20 lb) of
weld metal;
 The electroslag welding process welds only carbon- and
low-alloy steels and some stainless steels;
 Joints must be positioned in the vertical or near vertical
position;
 Once welding has started, it must be carried out to
completion or a defective start-stop area is likely to
result;
 Electroslag welding cannot be used on materials thinner
than about 13 millimeters (mm) (1/2 inch [in.]); and
 Complex material shapes may be difficult or impossible
Transverse and Longitudinal
Section through a 100 mm (4
in.)
Thick Electroslag Weld
APPLICATIONS

Many types of carbon steels can be joined using

electroslag welding. These include AISI 1020, AISI 1045,
ASTM A36, ASTM A441, and ASTM A515. They can
generally be welded without postweld heat treatment. In
addition to carbon steels, other steels can be
successfully welded using this process. They include AISI
4130, AISI 8620, ASTM A302, HY80, austenitic stainless
steels, ASTM A514, ingot iron, and ASTM A387. Most of
these steels require special electrodes and a
grain-refining postweld heat treatment to develop the
required weld or weld heat-affected-zone properties.