Submerged arc welding is a standard industrial process wherein an arc is formed between a workpiece and an electrode. It was invented in by the E. O. Paton Electric Welding Institute in Kyiv, Ukraine as a driving force behind the Second World War. One of the most notable applications of this invention is the T34 military tank.
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While this welding technology has been around for almost a century, it is still an essential choice for many industries.
Key Takeaways
What Is Submerged Arc Welding?
Submerged arc welding (SAW) is a welding method where similarly to other arc welding processes, the base metals are joined by forming an electric arc between the workpiece and an electrode.
SAW process&#;s defining element is how it protects the weld metal from atmospheric contamination. Submerged arc welding uses a powdered flux layer, generating shielding and slag while creating a smooth and clean weld. Other methods use shielding gas (MIG/TIG welding), flux-cored wire (FCAW), flux-coated electrode (SMAW), or controlled environment (plasma welding) for protecting the weld.
How Does the Submerged Arc Welding Process Work?
Submerged arc welding creates consistent welds by using a blanket of granulated flux. For this reason, the process can be operated only on positions that are flat and horizontal, with the weld advancing by either moving the welding system or the workpiece.
Flux is fed into the joint manually or by using a flux hopper. A single electrode or multiple wire electrode system is placed into the working area, surrounded by the flux blanket. Parameters such as the welding current, arc voltage, and wire feed speed are set depending on the type of metal, its thickness, and desired mechanical properties. Electric current is supplied to the electrodes, producing intense heat that melts and fuses the base material and the filler wire to the bead.
The molten metal cools down, creating strong uniform welds and reusable granular flux at the surface and slag underneath. A hopper collects the reusable flux, while slag is usually peeled off manually.
SAW produces high-quality welds with fewer weld defects than other processes. However, this does not mean that defects won&#;t ever occur. When they do, it&#;s generally related to wrongly set welding parameters.
Flux
Granular Flux
Granular flux inside a hopper is usually composed of oxides from aluminium, calcium, magnesium, manganese, silicon, titanium, and zirconium. This composition suits the type of electrode to achieve the metal&#;s desired properties as it chemically reacts as it melts.
Bonded Flux
Bonded flux is produced by drying the composition and slowly baking it, usually with a compound such as sodium silicate. As an advantage, bonded flux can contain alloying elements, offering flexibility for some applications and protection against rust.
Fused Flux
Fused flux is produced by melting the composition inside an electric furnace. The molten flux is formed into homogenous particles as it solidifies. It is excellent for creating consistent welds along the bead.
Wire Electrode
SAW uses a wire spool to feed the wire electrode into the weld. The wire&#;s thickness is usually between 1.6mm and 6mm. Electrodes may come in the form of solid, twisted, or cored wire and may be operated using different power sources.
Specific circumstances may need the use of modified wire electrodes and electrode systems to achieve the desired weld profile:
Twin-wire
Multiple wires
Single wire with hot/cold addition
Metal powder additive
Tubular wire
Multiple wire systems typically use a lead wire to improve penetration, while a trailing wire is used to add extra fill and improve the bead profile. Additional wires are used in the electrode system to add more deposition to the weld pool.
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Materials
Submerged arc welding process is used with the following materials:
Copper alloys
Low to medium-carbon steels
Low-alloy steels
Mild steels
Nickel-based alloys
Quenched and tempered steel
Stainless steels
Uranium alloys
Power Source
Submerged arc welding can operate on multiple power outputs, allowing it to manipulate the weld results. Multiple electrode systems enable SAW to run wires at different power sources, to better control the bead profile and penetration.
DCEP offers the most stability and penetration, while DCEN is optimal in increasing deposition rates. Running this welding process in AC is the middle ground where a balance between the two is achieved.
Applications and Industries
Submerged Arc Welding
Fabrication
SAW is one of the preferred welding processes in fabricating pressure vessels, pipes, and boilers due to its strength in longitudinal and circumferential welding. This welding operation achieves a smooth weld pool from the continuously fed electrode.
Shipbuilding
The flexibility of SAW process allows it to be performed both indoors and outdoors which makes it suitable for shipbuilding. It&#;s perfect for creating long, straight welds for heavy metals which make up ship parts.
Automotive
Metals used in the automotive and military industry are fit for SAW, along with the speed and efficiency it brings. This welding method is also perfect for automation, with the option to have multiple or single-pass welds based on the metal&#;s thickness.
Railways
The submerged arc process allows deep weld penetration, which is attractive to the railway industry.
Advantages of SAW
The blanket of granular flux creates minimal welding fume and spatter.
Allows performing semiautomatic or fully automatic welding.
Flexible for both indoor and outdoor applications.
Creates smooth, uniform and deep welds.
Around 50-90% of the flux is reusable and recyclable.
Limitations of SAW
Limited to flat and horizontal welding positions
A rather narrow range of weldable metals.
Requires post-welding slag removal.
Practically restricted to circumferential and long straight beads.
Precise parameters are required to achieve desired weld deposit since welds aren&#;t visible while welding.
Curious about submerged arc welding? It's a method that's all about joining big pieces of metal really well and without any mess. Imagine welding with a special material called flux covering the work area&#;that's what keeps everything clean and strong.
This method is super useful for big projects like ships, trains, and huge pipes. It's a clean, reliable way to weld that pros use when they need to get a lot done without any fuss. Want to see how submerged arc welding can tackle big welding jobs? Keep reading, and we'll show you how it's done.
Submerged arc welding (SAW) is a fast and efficient method that produces deep and neat welds. It uses a special covering called flux to make sure the welding arc and the melted metal stay clean and stable during the process.
Submerged arc welding is a process in which the heat required to fuse the metal is generated by an electric arc between the workpiece and a consumable electrode.
The arc is submerged beneath a layer of flux, which helps to stabilize the arc, refine the weld metal chemistry, and protect the molten pool from contamination.
Introduced in the s, submerged arc welding was developed to address the need for a method that could facilitate large-scale production and deliver consistent, high-quality welds.
This technique revolutionized the welding industry with its capacity to handle substantial weldments and high deposition rates.
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SAW differs from other arc welding processes by its use of a blanket of flux that shields the arc. This results in less spatter, no visible arc light, and minimal fume generation.
Compared to processes like MIG or TIG, sub arc welding is particularly suited for long, straight seams or heavy workpieces requiring thick joints.
: A vital element that cleans the weld, shapes the profile, and prevents oxidation.
: Continuous solid or cored wire fed into the weld pool.
: The heat source generated between the electrode and the metal.
: Operates under the flux, making it invisible during welding.
In SAW, your control over these core elements influences the quality and efficiency of the welding process. Proper selection and handling are crucial for achieving optimal results.
Explore the specifics of Submerged Arc Welding (SAW), where precision and understanding of the equipment, flux, mechanics, and operational settings play crucial roles in achieving quality welding outcomes.
Your successful engagement with sub arc welding begins with comprehending the necessary equipment.
A typical SAW setup includes a power source, flux hopper, wire feed mechanism, and electrodes.
The power source must be capable of providing a constant current to produce the required heat for welding.
Electrodes are typically fed from a spool, and their diameters are chosen based on the specific welding application.
Flux controls the welding atmosphere and stabilizes the arc.
When you engage in SAW, the flux is delivered from the flux hopper and covers the weld area to prevent contamination from the surrounding environment.
In addition to protecting the weld pool, fluxes can also alter the chemical composition of the weld by transferring alloying elements.
SAW is known for a high-deposition rate welding process involving the formation of an electric arc between the continuously-fed electrode and the workpiece.
As you operate, the wire feed mechanism efficiently delivers electrodes into the weld zone. This process ensures consistent quality by automating the feed rate, which is critical for maintaining a stable arc and smooth weld bead.
Two highly influential factors on the outcome of your SAW are the welding current and travel speed.
Adjusting the current modifies the heat input, affecting the penetration and bead profile. Travel speed, on the other hand, influences the weld bead's width and reinforcement.
A balance between these settings is paramount for the desired deposition rate and weld quality.
In the domain of sub arc welding (SAW), your choice of material and its intended application are crucial for the success of the welding process. Understanding their compatibility and the scope of their applications ensures optimal performance and longevity of the welded structures.
SAW is suited for a range of metals, where the productivity and efficiency of the process can be maximized. Notably, steels and stainless steels are frequently used materials. They accommodate a smooth welding experience due to their properties. Specifically:
: Ideal for structural purposes, given their strength and versatility.
: Preferred for projects requiring higher strength and toughness.
: Used for applications demanding resistance to corrosion.
Additionally, nickel-based alloys are also compatible with SAW, offering high performance in extreme conditions.
Also read: What Is Nickel Welding? Understanding the Process and Applications
Your projects may span various industries, and SAW is remarkably versatile in its applications. Here are a few specific uses:
: SAW&#;s capability to create strong, resilient joints makes it ideal for vessels that hold pressurized substances.
: For these components, SAW provides durable welds that can withstand the demands of temperature and pressure fluctuation.
: The process is a staple in the shipbuilding industry due to its efficiency and the large-scale workpieces involved.
: SAW is often the preferred method for constructing large steel frameworks, supporting the integrity of the structure.
Submerged arc welding (SAW), commonly referred to as sub arc welding, is a highly efficient and controlled process. Below you&#;ll find a thorough investigation into its performance and how it behaves under various operational parameters.
In sub arc welding, you&#;ll find that deposition rates are exceptionally high due to the covered arc and continuous feed of filler material.
This allows for welding thick-section workpieces with ease. The process is capable of joining materials with a thickness typically ranging from about 1/8 inch (3mm) to several inches.
The benefits of using sub arc welding are numerous. The process is clean with a minimal amount of spatter, resulting in a superior finish.
Additionally, the blanket of flux not only produces slag that protects the molten weld from contaminants but also minimizes fumes, enhancing the safety and cleanliness of your working environment.
High-quality welds
Minimal spatter and fumes
Suitable for thick materials
Enhanced safety due to reduced fume emission
Despite its advantages, sub arc welding also presents some constraints. Certain geometries may be challenging to weld, and the process is typically less versatile than others.
Overhead or vertical welding processes can be particularly complex with SAW because of the granular flux.
Limited to flat or horizontal-fillet welds
Complex slag removal process
Reduced versatility for varying geometries
Sub arc welding is economically advantageous, especially when dealing with large-scale production or thick materials.
Its automated nature leads to a decrease in labor costs and an increase in throughput. The high deposition rate of SAW means faster welding speed and therefore less time spent per weld.
Reduced labor costs
Increased welding speed
Economical for large-scale projects
Learning sub arc welding is straightforward, given its automated process controls which streamline the welding operation.
You do not need to possess high manual dexterity as required with some other welding processes, making the transition into SAW easier for operators.
Lesser manual skill required
Automated control for consistent results
Training focused on equipment setup and operation
Submerged Arc Welding (SAW) and Shielded Metal Arc Welding (SMAW) are distinct processes within the arc welding category.
SAW employs a continuously fed consumable electrode and utilizes a blanket of fusible granular flux to protect the weld zone from atmospheric contamination. This results in a smoother and more controlled weld that is commonly used for thicker materials.
: SAW is often automated or mechanized whereas SMAW is typically manual.
: SAW tends to provide a cleaner weld with less spatter compared to SMAW.
SMAW, also referred to as stick welding, involves a manual technique utilizing a consumable electrode coated in flux to lay the weld.
This process is versatile and can be used in various environments, but it yields a slower deposition rate than SAW.
: SMAW can be performed in diverse conditions including outdoors and on rusty or dirty metals.
: SMAW equipment is more portable compared to the heavier and more complex setups required for SAW.
Submerged arc welding is generally not suited for underwater welding applications due to the nature of its setup which requires a granular flux to cover the weld area.
Sub arc welding relies on a dry and controlled environment to maintain the integrity of the flux and ensure a high-quality weld.
: The necessity for a dry work area makes SAW impractical for underwater use.
: The flux used in SAW must remain dry; exposure to water can contaminate the weld pool leading to poor quality welds.
In contrast, specialized underwater welding techniques are applied for underwater operations which deal with the unique challenges posed by the marine environment.
Submerged arc welding (SAW) stands out as a stealthy and sturdy contender in the world of welding, delivering top-notch welds beneath a protective flux layer. A key player in heavy industrial tasks, this method promises strong, clean, and reliable welds for large, thick materials.
If you're drawn to the robust quality that SAW provides, consider looking into Arc Captain's selection of welding products. Engineered for performance and durability,
Take the next step in your welding journey and embrace the strength Arc Captain brings to every weld. Check out Arc Captain's products and ensure your next project stands the test of time.
The minimum thickness for submerged arc welding typically starts at around 1/8 inch (3 mm). This process is best suited for thicker materials because it offers deep penetration and a high deposition rate. While SAW can be adjusted for slightly thinner materials, other welding methods might be more effective and practical for sheets under 1/8 inch.
Submerged arc welding is one of the fastest welding processes available. It's known for its high deposition rates, allowing it to lay down more weld metal in a given time than most other welding methods.
The actual speed will depend on the specifics of the project, including material thickness and the machine's capabilities, but SAW is generally chosen for projects where speed and productivity are crucial considerations.
Submerged arc welding does not require an external shielding gas because the process itself uses a granular flux to protect the weld pool.
The flux covers the arc and molten metal, preventing contamination from the atmosphere. This characteristic of SAW makes it different from welding processes that do rely on shielding gases, like MIG or TIG welding.
MMA, or Manual Metal Arc welding, which is often called stick welding, is actually a type of arc welding. Arc welding is a broad term that encompasses a variety of welding processes, including MMA, TIG (Tungsten Inert Gas), and MIG (Metal Inert Gas) welding, along with Submerged Arc Welding (SAW).
MMA specifically uses a consumable electrode coated in flux to lay the weld, and it can be performed in diverse conditions, including outdoors and on rusty or dirty metals. Arc welding refers to the general principle of using an electric arc to generate heat and melt metals to be joined.
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