Submerged Arc Welding

By
L D Poyyara

Poyyara Consultants

SAW

Fusion Welding Process

Automatic / Semi Automatic
Arc Between Consumable Electrode And Work
Arc Covered Under granular Flux
Wire / Electrode Continuously Fed To Weld Pool
Wire / Arc Under Flux Moves Along The Groove
Wire, BM & Flux Close to Arc Melt Under Flux
On Cooling Weld Metal Solidifies
Molten Flux Forms Thick Slag Coating On Weld
Poyyara Consultants

SAW
Hopper
Flux

Wire

Flux

Slag
Weld

Power Source

Arc

Poyyara Consultants

Base Metal

Flux For SAW

Sodium Chloride
Potassium Chloride
Titanium Dioxide
Sodium Silicate
Deoxidizing Agents
Poyyara Consultants

Types Of Flux

Fused Flux
Agglomerated Flux
Neutral Flux
Active Flux

Poyyara Consultants

Types Of Flux
Neutral Flux
-Wire compatible to base metal
- Single flux suitable for several material

Active Flux
- Single flux suitable for specific application
- Wire may be different from basemetal
- To be welded within the recommended parameters
Poyyara Consultants

Function Of Flux In SAW

Stabilizes Arc
Prevents contamination of weld metal
Cleans the weld from unwanted impurities
Increases Fluidity of molten metal
Generates inert gas shielding while metal transfers
Forms slag after melting & covers weld
Allows deposited metal to cool slowly
Compensates alloying elements Within the weld
Eliminates spatter generation
Helps in even & uniform bead finish
Poyyara Consultants

Baking Requirements For Flux

Spread the loose Flux in a Tray Of baking Oven

Identify The Tray With The Quality/Grade Of Flux
Bake Tray in an Oven Between 300 C to 350 C
Baking Time 2Hrs to 3 Hrs
Reduce the temperature to 100 C to 150 C
Hold the Flux at this temperature till use

Poyyara Consultants

Why Baking Flux?

To remove the moisture (H2O)
To avoid possible cracking of weld due
to H2

Poyyara Consultants

How Does Moist Flux Generate

Crack Within Weld?
Moist Flux introduce atomic hydrogen at high
temperature in weld
On cooling, atomic hydrogen try to form
molecules
The reaction results in stresses and fine cracks
Cracks occur within hardened metal - HAZ
Known as Hydrogen Embrittlement or Under
Bead Crack or Delayed Crack
Poyyara Consultants

Reuse Of Flux
Flux May Be Reused Provided
- Weld Not Highly Critical In Impact / Chemistry
- Reuse Limited To Maximum Twice
- All Slag Particles Are sieved & Removed
- Rebaked If not Remained In Hot
- Minimum 50% Fresh Flux Well Mixed
- Customer Spec. Doesn't Prohibit The Same
Poyyara Consultants

Types Of Power Source

Thyrester DC
Rectifier DC
Motor Generator DC
Transformer - AC
Poyyara Consultants

Characteristic Of Power Source

Machine welding
Drooping Cons. A

Linear Cons. V

V1
V1
V2

V2

A1 A2

A
Poyyara Consultants

A1

A2

SAW Wire - Electrode

Consumable Electrode / Wire

Layer Wound On Spool / Coil
CS & LAS Wires Coated with Cu
Conducts Current and generates Arc
Chemistry Compatible To Base Metal
Grade Of Flux Can Be Same For CS & LAS
Wire melts & deposited as filler in joint

Poyyara Consultants

Typical Welding Parameter

Sr
no

Wire
mm

Current A

Voltage
V

Speed
mm/min

Dep. Rate
Per Arc Hr

1.6

200-300

22-26

750-1500

3 4 kgs

250-350

24-26

750-1250

3- 4.5 kgs

2.5

300-350

25-27

750-1250

4 4.5 kgs

400-500

28-30

500-100

5 5.5 kgs

550-650

30-32

400-750

5.5 - 7 kgs

600-800

30-34

350-700

6 - 8 kgs

Poyyara Consultants

Wire & Flux

CS wire
+
Neutral
Flux

Important Terminology used in

Critical SAW

Preheating
Post Heating or Dehydrogenation
Intermediate Stress leaving
Inter pass Temperature
Post Weld Heat Treatment

Poyyara Consultants

What Is Preheating?
Heating the base metal along the weld joint
to a predetermined minimum temperature
immediately before starting the weld.
Heating by Oxy fuel flame or electric
resistant coil
Heating from opposite side of welding
wherever possible
Temperature to be verified by thermo chalks
prior to starting the weld
Poyyara Consultants

Why Preheating?
Preheating eliminates possible cracking of weld
and HAZ
Applicable to
-Hardenable low alloy steels of all thickness
-Carbon steels of thickness above 25 mm.
-Restrained welds of all thickness
Preheating temperature vary from 75C to 200C
depending on hardenability of material, thickness
& joint restrain
Poyyara Consultants

How does Preheating Eliminate

Crack?
Preheating promotes slow cooling of weld
and HAZ
Slow cooling softens or prevents hardening
of weld and HAZ
Soft material not prone to crack even in
restrained condition

Poyyara Consultants

What Is Post Heating?

Raising the pre heating temperature of the weld
joint to a predetermined temperature range (250 C
to 350 C) for a minimum period of time (3 Hrs)
before the weld cools down to room temperature.
Post heating performed when welding is completed
or terminated any time in between.
Heating by Oxy fuel flame or electric resistant coil
Heating from opposite side of welding wherever
possible
Temperature verified by thermo chalks during the
period
Poyyara Consultants

Why Post Heating?

Post heating eliminates possible delayed
cracking of weld and HAZ
Applicable to
-Thicker hardenable low alloy steels
-Restrained hardenable welds of all
thickness
Post heating temperature and duration
depends on hardenability of material,
thickness & joint restrain
Poyyara Consultants

How does Post Heating Eliminate

Crack?
SAW introduces hydrogen in weld metal
Entrapped hydrogen in weld metal induces
delayed cracks unless removed before
cooling to room temperature
Retaining the weld at a higher temperature
for a longer duration allows the hydrogen to
come out of weld

Poyyara Consultants

What Is Intermediate Stress

Relieving?
Heat treating a subassembly in a furnace to
a predetermined cycle immediately on
completion of critical restrained weld joint /
joints without allowing the welds to go down
the pre heat temperature. Rate of heating,
Soaking temperature, Soaking time and rate
of cooling depends on material quality and
thickness
Applicable to
Highly restrained air hardenable material
Poyyara Consultants

Why Intermediate Stress

Relieving?
Restrained welds in air hardenable steel
highly prone to crack on cooling to room
temperature.
Cracks due to entrapped hydrogen and built
in stress
Intermediate stress relieving relieves built in
stresses and entrapped hydrogen making the
joint free from crack prone
Poyyara Consultants

What Is Inter- Pass Temperature?

The temperature of a previously layed weld
bead immediately before depositing the next
bead over it
Temperature to be verified by thermo chalk
prior to starting next bead
Applicable to
Stainless Steel
Carbon Steel & LAS with minimum
impact
Poyyara Consultants

Why Inter Pass Temperature?

Control on inter pass temperature avoids over
heating, there by
-Refines the weld metal with fine grains
-Improves the notch toughness properties
-Minimize the loss of alloying elements in
welds
-Reduces the distortion
Poyyara Consultants

What Is Post Weld Heat

Treatment?
Heat treating an assembly on completion of
all applicable welding, in an enclosed
furnace with controlled heating/cooling rate
and soaking at a specific temperature for a
specific time.
Rate of heating, Soaking temperature,
Soaking time and rate of cooling depends on
material quality and thickness
Applicable to
-All type of CS & LAS
Poyyara Consultants

Why Post Weld Heat Treatment?

Welded joints retain internal stresses within
the structure
HAZ of welds remains invariably hardened
Post Weld Heat Treatment relieves internal
stresses and softens HAZ. This reduces the
cracking tendency of the equipment in
service
Poyyara Consultants

Thanks

Poyyara Consultants