SUBMERGED ARC (SAW) WELDING
What is submerged arc welding?
A constantly fed electrode and the workpiece to be welded form an electric arc during the submerged arc welding (SAW) process of joining. When molten, the flux that surrounds and covers the arc allows for electrical transmission between the electrode and the metal that needs to be connected. The weld zone is further protected by the production of a protective gas barrier and slag.
Why is it called submerged arc welding?
Because the arc remains submerged in flux.
Why is it called submerged arc welding?
Because the arc remains submerged in flux.
Advantages and Disadvatages of Submerged Arc Welding
What are the submerged arc welding advantages?
Advantages of submerged arc welding
Disadvantages of submerged arc welding
- High deposition rates in submerged arc welding.
- High operating factors in mechanized applications.
- Deep weld penetration in submerged arc welding
- Sound welds are readily made (with good process design and control).
- High speed welding of thin sheet steels up to 5 m/min (16 ft/min) is possible.
- Minimal welding fume or arc light is emitted in submerged arc welding
- Practically no edge preparation is necessary in submerged arc welding
- The process is suitable for both indoor and outdoor works.
- Low distortion
- Welds produced are sound, uniform, ductile, corrosion resistant and have good impact value.
- Single pass welds can be made in thick plates with normal equipment in submerged arc welding
- The arc is always covered under a blanket of flux, thus there is no chance of spatter of weld.
- 50% to 90% of the flux is recoverable.
- Lends itself to the production of consistently high quality welds with minimum operator skills.
- Minimum of welding fume and of arc visibility (radiation).
- Well suited to welding thick sections.
- Suitable for welding carbon, low alloy and alloy steels.
- Relatively high metal deposition rates
Disadvantages of submerged arc welding
- Submerged arc welding is limited to ferrous (steel or stainless steels) and some nickel-based alloys.
- Submerged arc welding is normally limited to the 1F, 1G, and 2F positions.
- Submerged arc welding is normally limited to long straight seams or rotated pipes or vessels.
- Requires relatively troublesome flux handling systems.
- Flux and slag residue can present a health and safety concern.
- Requires inter-pass and post weld slag removal.
- Flat or horizontal position welding only
- Care required to preserve correct electrode alignment
- Tip and weld pool are underneath solid flux cover