Submerged arc welding:

Submerged Arc Weldingis

awelding process, which utilizes a
bare consumable metallic
electrode producing
anarcbetween itself and the work
piece within a granularshielding
fluxapplied around the weld.
The arc heats and melts both the
work pieces edges and the
electrode wire. The molten
electrode material is supplied to
the surfaces of the welded pieces,
fills the weld pool and joins the
work pieces.
Since the electrode is submerged
into the flux, the arc is invisible.
The flux is partially melts and
forms a slag protecting the weld
pool from oxidation and other
atmospheric contaminations.

Submerged arc welding:

Weld arc is shielded by a granular flux ,consisting of silica,
lime, manganese oxide, calcium fluoride and other
compounds.
Flux is fed into the weld zone by gravity flow through
nozzle
Thick layer of flux covers molten metal
Flux acts as a thermal insulator ,promoting deep
penetration of heat into the work piece
Consumable electrode is a coil of bare round wire fed
automatically through a tube
Power is supplied by 3-phase or 2-phase power lines

Submerged arc welding:

Flux
Fluxes used in SAW are granular fusible minerals containing oxides
of manganese, silicon, titanium, aluminium, calcium, zirconium,
magnesium and other compounds such as calcium fluoride.
Types
Sintered fluxes- produced by grinding the dry charge
together, processing into small balls & heating to, 1000
1100C in gas fired furnace. It is crushed to the desired fineness,
sieved, sized, & packed in suitable containers.
Fused fluxes- produced by mixing the ingredients, then
melting them in an electric furnace to form a chemically
homogeneous product, cooled and ground to the required
particle size. Smooth stable arcs, with welding currents up to
2000A and consistent weld metal properties, are the main
attraction of these fluxes.

Flux

Agglomerated fluxes- produced by finely

powdered ingredients are mixed and ground dry in a
mixer.

1
CaO MgO CaF2 Na2O K 2O (MnO FeO )
Basicoxides
2

Acidicoxides
SiO2 1 ( Al2O3 TiO2 ZrO2 )
2

Variations of the process.

Two-wire systems--same power source.

Two-wire systems--separate power source.
Three-wire systems--separate power source.
Strip electrode for surfacing.
Iron powder additions to the flux.
Long stickout welding.
Electrically "cold" filler wire.

Material applications

Carbon steels (structural and vessel

construction)
Low alloy steels
Stainless steels
Nickel-based alloys
Surfacing applications (wear-facing, build-up,
and corrosion resistant overlay of steels)

Advantages of submerged arc

welding

The deposition rate is high

Penetration of weld is high
Weld joints are strong and of good quality
Due to automation option, the production
speed is high
Welding operator skill required may not be high
Due to the shielding of arc by flux, fumes and
arc light is low

Limitations of SAW
Welding positions are limited
Good for only continuous and long length
welding
Possibilities of irregular wire feeding
Flux handling is time consuming and added
work
Post welding slag removal

Plasma Arc Welding

Plasma Arc Weldingis thewelding
processutilizing heat generated by a
constrictedarcstruck between a tungsten nonconsumable electrode and either the work piece
(transferred arc process) or water cooled
constricting nozzle (non-transferred arc
process).
Plasmais a gaseous mixture of positive ions,
electrons and neutral gas molecules.

Plasma Arc Welding

Plasma Arc Welding

Transferred arc processproduces plasma
jet of high energy density and may be used
for high speed welding and cutting of
Ceramics,steels,Aluminum alloys,Copper
alloys,Titanium alloys,Nickel alloys.
Non-transferred arc processproduces
plasma of relatively low energy density. It is
used for welding of various metals and for
plasma spraying(coating). Since the work
piece in non-transferred plasma arc welding
is not a part of electric circuit, the plasma
arc torch may move from one work piece to
other without extinguishing the arc.

Plasma Arc Welding

Advantages
Requires less operator skill due to good
tolerance of arc to
misalignments;
High welding rate;
High penetrating capability (keyhole effect)
Disadvantages
Expensive equipment;
High distortions and wide welds as a result of
high heat
input.