submerged arc weloding

 

                                                      Submerged Arc Welding

          Submerged Arc Welding (SAW) is a joining process that involves the formation of an electric arc between a continuously fed electrode and the workpiece to be welded. A blanket of powdered flux surrounds and covers the arc and, when molten, provides electrical conduction between the metal to be joined and the electrode. It also generates a protective gas shield and a slag, all of which protects the weld zone.

The make-up of the process can be viewed by reference to Figure 1 below

              








The general arrangement of the power source and controls, wire feed and flux dispensing are shown in Figure 2.



                                 

  Submerged arc welding is viewed as a high productivity process and is usually automated/mechanized in its form. The simplest application of the process uses a single wire. Selecting the correct wire diameter for a welded joint depends on many factors and the size of the available power source usually limits the diameter of the wire that can be used. While most power sources for this process are 1,000 amps, smaller power source may be used. A 3/32-in.-dia. wire through to a 5/32-in.-dia. wire will run in the 300 to 900 amps range using direct current and with the electrode positive (DC+)

     This welding process is typically suited to the longitudinal and circumferential butt welds required in the manufacture of pressure vessels and for joining plating and stiffeners in shipyards. Welding is positionally restricted and is normally carried out in the flat or horizontal positions because of the highly fluid weld pool, the molten slag, and the need to maintain a flux covering over the arc.

      As with all welding processes the selection of the consumables (wire and flux) and other parameters such as amps, volts and travel speed are intended to give a weld deposit that satisfies the objectives of the designer. In the case of this welding process, since the arc is submerged, the welding operator cannot see the molten weld pool and must, therefore, very accurately set the welding parameters and location of the welding nozzle within the joint.

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