Section 14

Submerged Arc Welding

Rev 2 April 2013

Submerged Arc Welding
Copyright TWI Ltd 2013

14

Submerged Arc Welding

14.1

Process
In submerged arc welding (SAW) an arc is struck between a continuous
bare wire and the parent plate. The arc, electrode end molten pool are
submerged in an agglomerated or fused powdered flux, which turns into a
gas and slag in its lower layers when subjected to the heat of the arc thus
protecting the weld from contamination. The wire electrode is fed
continuously by a feed unit of motor driven rollers which are usually voltagecontrolled to ensure an arc of constant length. A hopper fixed to the welding
head has a tube which spreads the flux in a continuous elongated mound in
front of the arc along the line of the intended weld and of sufficient depth to
submerge the arc completely so there is no spatter. The weld is shielded
from the atmosphere and there are no ultraviolet or infrared radiation effects
(see below). Unmelted flux is reclaimed for use. The use of powdered flux
restricts the process to the flat and horizontal-vertical welding positions.

Contact tube

Flux recovery
Consumable
electrode
Weld Metal

Arc

Weld Pool
Flux Feed
Parent Material

Slag

Submerged arc welding is able to use where high weld currents (owing to
the properties and functions of the flux) which give deep penetration and
high deposition rates. Generally DC+ve is used up to about 1000A because
it produces deep penetration. On some applications (ie cladding operations)
DC-ve is needed to reduce penetration and dilution. At higher currents or
with multiple electrode systems, AC is often preferred to avoid arc blow
(when used with multiple electrode systems, DC+ve is used for the lead arc
and AC for the trail arc).

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(A.C.)

Difficulties sometimes arise in ensuring conformity of the weld with a predetermined line owing to the obscuring effect of the flux. Where possible, a
guide wheel to run in the joint preparation is positioned in front of the
welding head and flux hoppers.
Submerged arc welding is widely used in the fabrication of ships, pressure
vessels, linepipe, railway carriages and where long welds are required. It
can be used to weld thicknesses from 5mm upwards.
Materials joined
Welding of carbon steels.
Welding low alloy steels (eg fine grained and creep resisting).
Welding stainless steels.
Welding nickel alloys.
Cladding to base metals to improve wear and corrosion resistance.

14.2

Fluxes
Flux is granular mineral compounds mixed to various formulations.
Welding characteristics: More stable arc, improved weld
appearance, easier slag removal, higher welding speeds.
Weld metal mechanical properties (YS, UTS and CEN)
amount of Mn and Si

Acid

Neutral

Basic

Highly basic

Type of fluxes

Fused

Agglomerated

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Fused fluxes are produced by the constituents being dry mixed, melted in an
electric furnace then granulated by pouring the molten mixture into water or
on to an ice block. Subsequently these particles are crushed and screened
to yield a uniform glass-like product.
Advantages of fused fluxes
Good chemical homogeneity.
Less hygroscopic so handling and storage are easier.
Fines (fine powders) can be removed without changes in composition.
Easily recycled through the system without significant change in particle
size or composition.
Disadvantages of fused fluxes
Limitations in composition as some components, such as basic
carbonates unable to withstand the melting process.
Difficult to add deoxidisers and ferro-alloys (due to segregation or
extremely high loss).
In agglomerated fluxes constituents may be bonded by mixing the dry
constituents with potassium or sodium silicate and the wet mixture is then
pelletised, dried, crushed and screened to size.
Advantages of agglomerated fluxes
Deoxidisers and alloying elements can easily be added to the flux to
adjust the weld metal composition.
Allow a thicker flux layer when welding.
Can be identified by colour and shape.
Disadvantages of agglomerated fluxes
Generally more hygroscopic (baking hardly practical).
Gas may evolve from the slag as it is melted, leading to porosity.
May be changes in weld metal chemical composition from the
segregation of fine particles produced by the mechanical handling of the
granulated flux.

14.3

Process variables
Several variables when changed can have an effect on the weld
appearance and mechanical properties:

Welding current.
Type of flux and particle distribution.
Arc voltage.
Travel speed.
Electrode size.
Electrode extension.
Type of electrode.
Width and depth of the layer of flux.

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Electrode angle (leading, trailing).

Polarity.
Single, double or multi-wire system.

14.3.1 Welding current

Increasing current increases penetration and wire melt-off rate.

350A

500A

650A

Welding current effect on weld profile (2.4mm electrode diameter, 35V arc voltage
and 61cm/min travel speed).

Excessively high current produces a deep penetrating arc with a

tendency to burn-through, undercut or a high, narrow bead prone to
solidification cracking.
Excessively low current produces an unstable arc, lack of penetration
and possibly a lack of fusion.

14.3.2 Arc voltage

Arc voltage adjustment varies the length of the arc between the electrode
and the molten weld metal. As it increases, the arc length increases and
vice versa. Voltage principally determines the shape of the weld bead crosssection and its external appearance.

25V

35V

45V

Arc voltage effect on weld profile 2.4mm electrode diameter, 500A welding
current and 61cm/min travel speed.
Increasing the arc voltage with constant current and travel speed will:

Produce a flatter, wider bead.

Increase flux consumption.
Tend to reduce porosity caused by rust or scale on steel.
Help to bridge excessive root opening when fit-up is poor.
Increase pick-up of alloying elements from the flux if present.

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Excessively high arc voltage will:

Produce a wide bead shape subject to solidification cracking.

Make slag removal difficult in groove welds.
Produce a concave-shaped fillet weld that may be subject to cracking.
Increase undercut along the edge(s) of fillet welds.
Over-alloy the weld metal via the flux.

Reducing the arc voltage with constant current and travel speed will produce
a stiffer arc which improves penetration in a deep weld groove and resists
arc blow.
Excessively low arc voltage will:

Produce a high, narrow bead.

Cause difficult slag removal along the weld toes.

14.3.3 Travel speed

If travel speed is increased:

Heat input per unit length of weld decreases.

Less filler metal is applied per unit length of weld therefore less excess
weld metal.
Penetration decreases so the weld bead becomes smaller.

305mm/min

610mm/min

1220mm/min

Travel speed effect on weld profile (2.4mm electrode diameter, 500A welding
current and 35V arc voltage).

14.3.4

Electrode size affects

Weld bead shape and depth of penetration at a given current

A high current density results in a stiff arc that penetrates into the base
metal. Conversely, a lower current density in the same size electrode
results in a soft arc that is less penetrating.

Deposition rate
At any given amperage setting, a small diameter electrode will have a
higher current density and deposition rate of molten metal than a larger
diameter electrode. However, a larger diameter electrode can carry more
current than a smaller one, so can ultimately produce a higher deposition
rate at higher amperage.

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3.2mm

4mm

5mm

Electrode size effect on weld profile (600A welding current, 30V arc voltage and
76cm/min travel speed).

14.3.5

Electrode extension
The electrode extension is the distance the continuous electrode protrudes
beyond the contact tip. At high current densities resistance heating of the
electrode between the contact tip and the arc can be to increase the
electrode melting rate (as much as 25-50%). The longer the extension, the
greater the amount of heating and the higher the melting rate but
drecreases penetration and weld bead width (see below).

30mm

14.3.6

45mm

60mm

80mm

Type of electrode
An electrode with low electrical conductivity, such as stainless steel, can
with a normal electrode extension, experience greater resistance heating.
Thus for the same size electrode and current, the melting rate of a stainless
steel electrode will be higher than that of a carbon steel electrode.

14.3.7 Width and depth of flux

The width and depth of the layer of granular flux influence the appearance
and soundness of the finished weld as well as the welding action. If the
granular layer is too deep, the arc is too confined and a rough weld with a
rope-like appearance is likely to result and it may produce local flat areas on
the surface often referred to as gas flats. The gases generated during
welding cannot readily escape and the surface of the molten weld metal is
irregularly distorted. If the granular layer is too shallow the arc will not be
entirely submerged in flux, flashing and spattering will occur and the weld
will have a poor appearance and may show porosity.

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14.4

Storage and care of consumables

Care must be taken with fluxes supplied for SAW which, although they may
be dry when packaged, may be exposed to high humidity during storage. In
such cases they should be dried as per the manufacturer's
recommendations before use or porosity or cracking may result.
Ferrous wire coils supplied as continuous feeding electrodes are usually
copper-coated which provides some corrosion resistance, ensures good
electrical contacts and helps in smooth feeding. Rust and mechanical
damage should be avoided in such products as they interrupt smooth
feeding of the electrode. Rust is detrimental to weld quality generally since it
is hygroscopic (may contain or absorb moisture) so can lead to hydrogen
induced cracking.
Contamination by carbon-containing materials such as oil, grease, paint and
drawing lubricants, is especially harmful with ferrous metals. Carbon pick-up
in the weld metal can cause a marked and usually undesirable change in
properties. Such contaminants may also result in hydrogen being absorbed
in the weld pool.
Welders should always follow the manufacturer's recommendations for
consumables storage and handling.

14.5

Power sources
In arc welding it is principally the current which determines the amount of
heat generated and this controls the melting of the electrode and parent
metal and also such factors as penetration and bead shape and size.
Voltage and arc length are also important factors with increasing voltage
leading to increasing arc length and vice/versa. Usually in SAW a constant
voltage or flat characteristic power source is used.
Power can be supplied from a welding generator with a flat characteristic or
a transformer/rectifier arranged to give output voltages of approximately 1450V and current according to the output of the unit, can be in excess of
1000A.

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