05 - Saw

Istituto Italiano della Saldatura
ENTE MORALE
Submerged arc welding
SUBMERGED ARC WELDING
ENTE MORALE
2/29
Features
The joining of metals is produced by heating
with an arc or arcs between a bare metal
electrode or electrodes and the work.
The arc is shielded by a blanket of granular
fusible material on the work.
Filler metal is obtained from the electrode
with a possible a supplementary welding
wire.
The flux close to the arc melts and intermixes
with the molten weld metal, helping to purify
and fortify it .
The flux forms a glass-like slag that is lighter
in weight than the deposited weld metal and
floats on the surface as a protective cover;
therefore the arc is not visible.
ENTE MORALE
3/29
Advantages, limitations and major use
Advantages
high quality of the weld metal.
extremely high deposition rate and speed.
smooth, uniform finished weld with no spatter.
little or no smoke, no arc flash, thus minimal need for
protective clothing.
normally, no involvement of manipulative skills.
Limitations:
Welding positions
In semiautomatic submerged arc welding, the inability
to see the arc and puddle can be a disadvantage in
reaching the root of a groove weld and properly filling
or sizing.
The submerged arc process is widely used in heavy steel plate fabrication work
(welding of structural shapes, longitudinal seam of larger diameter pipe,
manufacture of machine components for all types of heavy industry, manufacture
of vessels and tanks for pressure and storage use).
The high metallurgical properties make it a common process also for pressure
vessels manufacturing (with every king of steel and weldable nickel alloy)
It is also used for surfacing and buildup work, maintenance, and repair.
ENTE MORALE
4/29
Field of applications and use
Metals weldable and thickness range. Submerged arc
welding is used to weld low- and medium-carbon steels,
low-alloy high-strength steels, quenched and tempered
steels, many stainless steels
and some nickel alloys.
Experimentally, it has been used
to weld certain copper alloys,
nickel alloys, and even uranium.
ENTE MORALE
5/29
Equipment
ENTE MORALE
6/29
Welding equipment
The power source for submerged arc welding must be rated
for a 100 percent duty cycle, with size from 300 amperes to
1500 amperes
Direct current power is used for semiautomatic applications,
but alternating current power is used primarily with the
machine or the automatic method.
For semiautomatic application, a welding gun and cable
assembly are used to carry the electrode and current and to
provide the flux at the arc.
For automatic welding, the torch is attached to
the . the wire feed motor and includes current pickup tips for
transmitting the welding current to the electrode wire. The
flux hopper is normally attached to torch, and may have
magnetically operated valves which can be opened or closed
by the control system.
ENTE MORALE
7/29
DCEP is mainly in welding, as it gives higher penetration
DCEN increases wire feed rate, results in lower penetration and (lower
dilution rates); it is mainly used for cladding;
AC results in intermediate properties, giving neglectable magnetic blow
effects
Welding current
Welding current affects:
Wire feed rate;
Depth of penetration;
Fused flux.
In submerged arc welding, current
may range in very wide fields of
work
ENTE MORALE
8/29
Welding Voltage
The arc voltage is varied within narrower limits than welding current; it
affects:
Wideness of each pass
Amount of flux involved in welding
High voltages will cause the bead to be wider and flatter. Extremely high arc
voltage should be avoided, since it can cause porosities and cracking. Higher
arc voltage also increases the amount of flux consumed.
The low arc voltage produces a stiffer arc that improves penetration,
particularly in the bottom of deep grooves. If the voltage is too low, a very
narrow bead will result. With a slag difficult to be removed.
ENTE MORALE
9/29
Welding speed
Travel speed influences both bead width and penetration.
Faster travel speeds produce narrower beads that have less
penetration. This can be an advantage for sheet metal welding where
small beads and minimum penetration are required. If speeds are too
fast, however, there is a tendency for undercut and porosity, since the
weld freezes quicker.
If the travel speed is too slow, the electrode stays in the weld puddle
too long. This creates poor bead shape and may cause excessive
spatter and flash through the layer of flux.
ENTE MORALE
10/29
Other welding variables
The distance between the current
pickup tip and the arc, called
electrode stickout, has a
considerable effect on the weld.
If the stickout is increased, it will
cause preheating of the electrode
wire:
increase of the deposition rate.
the penetration into the base metal
decreases.
Normal values are 25 to 38 mm
(in general 8 times the wire
diameter)
Corrente [A]
D
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[
K
g
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]
25 mm
75 mm
ENTE MORALE
11/29
AS THERE IS NO VISUAL CHECK DURING WELDING,
QUALIFICATION OF WELDING PROCEDURES
BECOMES VERY IMPORTANT
Other welding variables
Depth of the flux layer
If it is too thin, there will be too much
arcing through the flux or arc flash.
Resulting in porosity.
If the flux depth is too heavy, the
weld may be narrow and humped.
Wire diameter
Smaller diameters will result in
higher deposition rate and
penetration
ENTE MORALE
12/29
Welding consumables
SUBMERGED ARC FLUXES
FUSED FLUXES AGGOLMERATED FLUXES MIXED FLUXES
ACID NEUTRAL
BASIC
The weld metal properties depend on the flux wire combination
ENTE MORALE
13/29
Fused fluxes
The fabrication process is composed by the following phases
- Melting of the components
- Solidification in vat
- Milling in appropriately sized particles
This results in:
- poor metallurgical effects
- high welding speeds
- possibility of reusing the flux, and neglectable storage problems
Moreover the weld bead is enriched in Si content
USED WITH MEDIUM/HIG Mn WIRES
ENTE MORALE
14/29
Agglomerated fluxes
The fluxed are produced by:
Milling previous to heating
Heating in Owens to agglomerate (with specific
substances)
This results in:
More fitted results for the chemical properties of
the weld metal
Problems for flux storage and treatment
Difficulties in recycling the flux
Chemical properties are strongly dependent on
welding parameters
USED WITH LOW Mn WIRES
ENTE MORALE
15/29
EN 756:1997 : Wires and wire-flux combination
ENTE MORALE
16/29
EN 756:1997 : Wires and wire-flux combination
Wire-flux combination EN 756 - S 46 3 AB S2
- S is for Submerged arc welding
- 46 is for the tensile properties
of the weld metal
- 3 is for the fracture toughness
(47J)
- AB is for the composition of
the flux
- S2 is for the wire composition
ENTE MORALE
17/29
UNI EN 760: Submerged arc welding fluxes
Welding flux EN 760 - S F CS 1 67 AC H10
- S is for Submerged arc welding
- F is the type o flux (F/A/M)
- CS is the composition of the flux
- 1 is for the application and the class
- 6 7 are referred to metallurgical
behavior
- AC is the type of current (AC/DC)
- H 10 is the Hydrogen content
metallurgical behaviour
Cladding and hardfacing
Welding of high alloyed steels and nichel alloys
Welding of low alloyed steels
3
2
1
Application and class
Cr
Cr
Mn
C
C
Si
Digits
ENTE MORALE
18/29
Flux wire combination AWS A 5.17
AWS A 5.17 F S X X X - E X XX K - HX
Reference standard
SAW flux
If reported, refers to a re-usable flux
Tensile strength, divided for 10.000 (es. 7 is for 70
KPsi, about 500 Mpa)
Heat treatment to obtain such properties
(A: As welded; P: PWHT)
Fracture toughness (20 ft x lb), to be multiplied by -10
(es. 6 = 20 ft x lb @ -60 C)
SAW electrode
Type of wire:
- L: low Mn
- M: medium Mn
- H: High Mn
- C: Cored
- G: Without requirements
- CG: cored without requirements
Carbon content, x 100
If present, high Si wire
Optional
(Hdm) in ml/100g:
- H2: <2 ml/100g
- H4: 24 ml/100g
- H8: 816 ml/100g
- H16: >16 ml/100g
ENTE MORALE
19/29
AWS A 5.17
ENTE MORALE
20/29
Flux wire combination: AWS A 5.17
ENTE MORALE
21/29
Flux wire combination: AWS A 5.17M
ENTE MORALE
22/29
Joint preparation: High current welding
ENTE MORALE
23/29
Welding of T-Joints
ENTE MORALE
24/29
Multipass welding
Narrow gap welding
ENTE MORALE
25/29
Application of the process: tube welding
ENTE MORALE
26/29
Application of the process: pressure vessels
Adaptative control
ENTE MORALE
27/29
Narrow gap welding
Narrow Gap - tandem welding unit
ENTE MORALE
28/29
Multiple wire welding
Two different techniques are available:
Tandem
Twin arc
Testa saldante a 5 fili (Long. Tubi)
Testa saldante a 3 fili (Panel line)
ENTE MORALE
29/29
Cladding

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