SUBMERGED ARC WELDING Miller.PREFACE The material contained within is current technical information on the application of the Submerged Arc Welding (SAW) process. It goes ‘without saying that new, up-to-date technical data is changing continuously. However, basic information is always beneficial, and it is hoped that this book will be helpful in that respect. All recommendations in this book are approximate values. We suggest that any welds or weldments be tested to assure that all codes and specifications are met. MILLER Electric Mfg. Co. TABLE OF CONTENTS General Stes Making the Weld Starting... -.eee eee Equipment ‘Sharp Wire Starts... Power Sources ‘Steel Woo! Starts ‘Constant Current cae Constant Potential «<=... Scratch Stars..... Molten Pool Starts | Altemating Current Rotract Wire Starts. Wire Feeding... High Frequency Starts . Semiautomatic Submerged Arc 2.2... Voltage....... Flux Feeding ........0sesccssrevsere Amperage /Wire Feod Speed Arc Starting... Seen Travel Speed : Gun Positions «2... Electrode Size . Electrical Extensions. - Electrode Extension Guns and Flux Systems . Polarity... eeeeeerece Fixtures eee Welding Hints Coane, Circumferential Welds. Fluxes i 8 Fillet Welds . Fused ee 8 Lap Welds Bonded 2020201.) ‘ 9 ‘Weld Defects and Troubleshooting Agglomerated..... Peete eaeeme ‘Mechanically Mixed : 9 ‘Special Applications. Particle Size. 9 Cladding Wire and Flux Identification. 210 Stainless Steel Wires... a 210 Glossary. Preparing to Weld Joint Cleaning wo, “Joint Fitup oe 15 Bead Placement Sea Flux Depth 5 Preheat and interpass Temperature 15 ©COPYRIGHT 1982 MILLER ELECTRIC MFG. CO. (Rev. 11/85) sel? nq veld a7 a? “a7 218 8 nes) 219 ng bak mn 24 24SUBMERGED ARC WELDING GENERAL Submerged Arc Welding (SAW), of Sub Arc a generally referred to, is @ unique welding process because there is no visible evidence that a wold is being made. The welding zone is completely shielded by a blanket of granular flux. Exposed arc eye protection is ot normally used since the arc should be completely covered. The welding operator must, however, employ 900d safety practices to assure protection of the eyes and face. By contacting the American Welding Society (AWS), 560 NW LeJeune Road, P.O. Box 351040, Miami,” Florida 33135. Safety Manual 2.49.1 Safety in Welding and Cutting can be obtained. Any are welding process can produce furnes and gases. that could be harmful to health. Always maintain good ventilation in welding areas. Use special care in confined spaces. ‘The American Welding Society (AWS) defines Sub- merged Arc Welding (SAW) as follows: “An arc welding process which produces coales- ‘cance of metals by heating them with an arc or arcs between a bare metal electrode or electrodes and the work. The arc and molten metal are shielded by 2 blanket of granular, fusible material on the work. Pressure is not used, end filler metal is obtained from the electrodes and Sometimes from a supplemental source (welding rod, flux or metal granules)."” ‘This process has been used successfully for years to pro- duce high quality welds in compliance with such code agencies as: ASME, AWS, API and the American Bureau of Shipping. Submerged Arc Welding has found usage in nearly all industries. ‘Semiautomatic and Automatic Sub Arc have some ad- vantages, such as: 1, Higher deposition enhances welding speed or produc- tion. 2. Deep penetration in some cases may eliminate joint preparation. 3, Excellent mechanical properties for high quality code and X ray requirements. 4. Improves welding operator comfort and appesl. EQUIPMENT ‘The basic welding equipment requirements for the pro- cess include a power source, wire feed control and rive assembly, 8 welding gun, a flux delivery system and fix turing. ‘Submerged Are Welding Power Source POWER SOURCES ‘The POWER SOURCE is usually the first piece of equip- ment selected. Because the process is often fully ‘automated, the power source must be capable of an out ut and of a duty cycle to match the operation. The thickness of the material to be welded will dictate amperage requirements. Light gauge material may re- Quire as few as 300 amps, while heavy material can re- quire 1,000 amps or more. Constant Current With a CONSTANT CURRENT POWER SOURCE (this type is characterized by the relatively steep downward slope of the volt/amp curve), a voltage sensing wire feoder is sometimes used. The voltage sensing feeder is designed to increase the speed of the wire feed motor When the arc voltage increases and reduces the speed of the wire fead motor when the voltage decreases. This ‘maintains a fairly constant arc voltage and arc length, but does not give a consistent deposition rate.