SAW joint preparations

Typical welding data and recommended joint preparations for submerged arc welding. Non and low-alloyed steels
Type of joint Plate Wire thickness diameter
mm 6 mm 3.0 3.0 8 4.0 4.0 10 4.0 4.0 12 4.0 4.0 14 4.0 4.0 1 2 1 2 1 2 1 2 1 2

Run no

Welding Arc current voltage

A 320 350 450 500 550 600 600 650 700 750 V 32 32 32 32 33 33 33 33 34 34

Welding speed
cm/min 80

Type of joint

Throat Wire thickness diameter mm mm

3 4 1 x 3.0 1 x 3.0 1 x 4.0 1 x 3.0 1 x 3.0 4 1 x 3.0 1 x 3.0 1 x 3.0 1 x 3.0

Run no
1 1 1 1 2 1 1 1 1

Welding Arc current voltage A V

500 500 650 500 620 600 600 650 750 28 28 30 29 32 32 32 32 32

Welding speed cm/min

80 60 60 50 60 100 60 55 45

75

5 7

70 5 6 55 7 Twin Arc 4

60

for all procedures: 1 run from back side: 4.0 1 680 32 50

2 x 1.6 2 x 2.0

1 1

800 800

32 32

115 100

5 Cored wire

14 16
50 - 60

4.0 4.0 4.0

1 1 2 1 2 1 2 3 1 2 3 4-5 1 2 3 4-5 6-8 1 2 3 4-5 6-n 1

650 580 750 580 750 580 750 750 580 750 750 750 580 750 750 750 750 580 750 750 750 750

26 26 34 26 34 26 30 34 26 30 30 32 26 30 30 32 32 26 30 30 32 32

50 60 60 60 50 60 60 60 60 60 60 50 60 60 60 50 50 60 60 60 50 50

5 Tandem DC+, AC 4

2 x 2.4

800

30

120

18

4.0 4.0

4.0 4.0

1 (DC+) 800 1 (AC) 700

32 36

140

20

4.0 4.0 4.0

Tandem DC+, AC 4 4.0 4.0 5 4.0 4.0 1 (DC+) 800 1 (AC) 700 32 36 32 36 90 140

Gap: as small as possible; in locations where gap > 1 mm: MMA or MAG root run.

25

4.0 4.0 4.0 4.0

1 (DC+) 800 1 (AC) 700

30

4.0 4.0 4.0 4.0 4.0

Note: If a cored wire is used, an extra 2 volts are required in the high current range (>600A) to spread the extra weld metal (25-30%).

40

4.0 4.0 4.0 4.0 4.0

14 4.0 4.0 4.0 16 4.0 4.0 4.0 18

50 - 60

MAG or MMA 550 600 680 26 30 32 50 50 50

2 3 4 1 2 3 4-5 1

MAG or MMA 550 650 680 26 32 32 50 50 50

MAG or MMA 550 650 680 26 30 32 50 50 50

4.0 4.0 4.0

2 3-4 5-6 1

20 4.0

MAG or MMA 550 650 750 680 26 30 32 32 50 50 50 50

2 3-4 5-6 7 1

Welded from 1 side root run: MMA or MAG. Thickness of root run 5 mm. 22

4.0 4.0 4.0

MAG or MMA 550 650 750 680 26 30 32 32 50 50 50 50

4.0 4.0 4.0 4.0

2 3-4 5 - n-2 n-1 - n

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SAW joint preparations

Stainless steels
Type of joint Plate thickness mm
6

Wire diameter mm
2.4 2.4 3.2

Run No.

Welding current A
300 400 400 500 350 450 450 550 450 550

Arc voltage V
33 34 34 34 33 34 34 34 34 34

Welding speed cm/min

40 40 100 130 40 40 55 55 100 130

1 2 1 2 1 2 1 2 1 2

3.2
2

2.4 2.4 3.2 3.2 4 4

10

2.4 2.4 2.4 3.2

1 2 3 1 2 1 2 1 2 1 2 3-5

420 420 420 500 500 550 550 600 600 575 600 600

30 32 32 30 32 31 34 32 34 31 32 34

45 40 40 55 55 65 100 60 80 60 60 65

60 1 1.3 2 2 gap: 0-2 mm

3.2 4 4 12 4 4 20 4 4 4

60 1.4 2 0-2 mm gap: 2 mm 2.3

25

4 4 4 4

1 2 3 4-8

550 600 600 600

32 34 34 34

60 50 50 60

90

6
2

2 3.2 3.2

1-n 1-n 1-n

300 380 450

31 32 34

60 65 70

10 16

70

8
5

4 4

1 2 1 2

450 550 500 600

32 34 32 34

90 85 65 85

10

4 4

70

12
5

4 4

1 2 1 2

500 600 550 600

32 34 32 34

60 70 60 60

14

4 4

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Trouble shooting guide

Defect
Porosity

Possible causes
Rusty plate Oily plate Contaminated plate Wet plate Primer Flux cover too shallow, arc flashes Wet flux Magnetic arc blow Flux becomes too fine Defective root run with MMA

Remedies
Wire brush or grind plate Degrease or preheat Use active flux or killed wire Preheat plate Remove primer Increase flux feeding Dry flux according to instructions on bag Weld towards earth clamp or split earth and attach at ends Add at least 1 part new flux to 3 parts of recycled flux Weld defect free root run; possibly change to MAG Weld towards earth clamp or split earth and attach at ends Adjust welding parameters Adjust alignment Reduce voltage Reduce voltage Reduce current Adjust welding parameters Check interpass temperature Modify joint preparation Increase welding speed Decrease current Reduce current Adjust fit-up Increase root face Increase welding speed Increase rotation speed Adjust position Decrease voltage/current Check flux selection Adjust welding parameters Decrease welding speed Reduce root gap Refer to ESAB Adjust welding parameters Reduce all possibilities for hydrogen occurrence

Undercut

Arc blow Welding speed too high Wire alignment incorrect Voltage too high

Slag sticking

Voltage too high Current too high Poor weld bead profile Hot plate Incorrect joint preparation

Excessive reinforcement Welding speed too low Current too high Burn through Current too high Poor fit-up Root face too small Welding speed too low Weld metal running Rotation of work piece too slow Incorrect wire position Too high voltage/current Flux too fluid Longitudinal cracks Convex reinforcement Elongated weld pool Poor fit-up Wrong consumable selection Weld depth to width ratio > 1 Weld metal hydrogen

Insufficient penetration and excessive reinforcement; also misaligned.

Weld depth to width ratio > 1 and relatively large amount of impurities in base material (S, P, Nb). 81

Trouble shooting guide, ctd.

Defect
Transverse cracks

Possible causes
Cooling rate too high Excessive restraint Too high heat input Wrong consumable selection

Remedies
Increase preheat / interpass temperature Preheat or redesign joint Adjust welding parameters Refer to ESAB Adjust welding parameters Reduce flux height Reduce voltage Weld towards earth clamp or split earth and attach at ends Check wire feed pressure and ensure smooth wire feeding Refer to power source supplier Weld towards earth clamp or split earth and attach at ends Reduce speed Check wire feed pressure and ensure smooth wire feeding Create a consistent joint preparation including tack welds Check earth connections Check if leads are over heated Use AC current Reduce voltage / wire extension Move earth closer Check wire feed pressure and ensure smooth wire feeding Add at least one part of new flux to three parts of recycled flux. Replace / repair extractor Adjust welding parameters Adjust welding parameters Redesign joint Adjust welding parameters Increase preheat / interpass temperature Adjust welding parameters Adjust welding parameters Increase prepartion angle Adjust welding parameters

Rough irregular bead

Excessive heat input Flux cover too high Voltage too high

Erratic arc

Arc blow Wire feed problems Power source failure

Loss of reinforcement

Arc blow Welding speed too high Wire feed problems Irregular tack welds

Arc instability

Poor earth Leads frayed Presence of large steel mass Deep groove Earthing too distant

Arc extinguished Flux dust

Wire feed problem Excessive recycling of flux Faulty dust extractor

Insufficient penetration

Current too low Welding speed too high Wrong joint preparation

Cold laps

Heat input too low Plate temperature low Too high travelling speed

Slag inclusions

Flux trapped in preparation Plate preparation angle too small Insufficient penetration

Guidelines
Recommended current ranges (single wire) Diameter (mm) 2.4, 2.5 3.0, 3.2 4.0 Current ( amps) 300 - 500 350 - 600 400 - 850

Electrode extension should be 10 times the wire diameter Flux height should be around 30mm; the lower the better for degasing of the weld pool but there should be enough to prevent arc flashing

Do not hesitate to contact ESAB for advice in case of persistent problems or defects.

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