NITTETSU High Efficiency Welding Process

219

SUBNAP WELDING PROCESS

High Quality and Low Cost Welding Process for Thick Steel Plates
SUBNAP Welding Process is a narrow gap submerged arc welding process for the thick plates and has the following characteristics.

CHARACTERISTICS
1. It is possible to shorten welding time, save welding materials and greatly reduce welding costs. 2. Any submerged arc welding machine and power source at hand can be used by just changing the nozzle to a long tip of 8~10mm diameter or a rectangular cross sectional nozzle of 8~10mm width covered by heat proof insulating tape or a tube. 3. Mechanical properties of weld metal are the same or better than those of conventional submerged arc welding process. 4. High efficiency and better bead appearance are obtained by applying tandem welding with a short distance between electrodes of 7~13mm. 5. Gas cut grooves can be welded. n WELDING MATERIALS
Base metal ASTM A516 Gr60, 65, 70 ASTM A516 Gr70 ASTM A299 ASTM A516 Gr60, 65, 70 ASTM A537 C1 ASTM A533B, A302B ASTM A387Gr11, 12, C1, C2 ASTM A387Gr22, C1, C2 SUS304, SUS304L Wire NITTETSU Y-D NITTETSU Y-E NITTETSU Y-DM3 NITTETSU Y-36E NITTETSU Y-204 NITTETSU Y-511 Flux NITTETSU NF-1 NITTETSU NB-250L NITTETSU NF-250 NITTETSU NF-250* NITTETSU BF-350 Characteristics of Flux Neutral type fused flux High wire melting speed Basic type bonded flux High notch toughness Basic type fused flux

NITTETSU Y-521H NITTETSU Y-308 NITTETSU Y-308L

NITTETSU NB-250M Basic type fused flux Basic type bonded flux * M Type

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n STANDARD WELDING CONDITIONS FOR ONE-LAYER TWO-PASS SUBNAP WELDING PROCESS Groove Geometry mm
2 B.P

Number Wire of Dia. Electrode mm AC Single B.P 4.0 F.P

Layer 1 (1-pass) 2 Final (2-pass) 1 (1-pass) 2 Final (2-pass) 1 (1-pass) B.P

Welding Conditions ElecCurrent Voltage Speed trode A V cm/min 500 27 (32) 25 Single 600 500 600 Single L T Single L T 500 500 500 500 500 500 28 (33) 27 (32) 28 (33) 27 (32) 27 (29) 27 (29) 27 (32) 27 (29) 27 (29) 30 25 30 25 50 (55) 25 50 (55)

200

154

40

8R 2

ACAC Tandem

2 Final (2-pass) 1 (1-pass)

3.2 F.P

F.P

2 Final (2-pass)

Note 1. Voltage and speed in ( ) are for NITTETSU NF-1 and others for NITTETSU NF-250. 2. Distance between electrodes for tandem welding is 10mm. 3. Suitable wire center position for two-pass welding is 5~6mm from groove side wall.

n STANDARD WELDING CONDITIONS FOR STAINLESS STEEL SUBNAP WELDING PROCESS Groove Geometry mm
50

Wire Dia. mm

Layer

Welding Conditions Current Voltage Speed Pass A V cm/min 1 450 500 550 32 32 32 45 40 35

8R TIG 10

100

4.0

1-layer 2-pass

2~3 4 Final

Note Flux: NITTETSU BF-350

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221

CUT WIRE SUBMERGED ARC WELDING PROCESS

High Efficiency Submerged Arc Welding Using Cut Wire
Cut Wire Submerged Arc Welding Process is to carry out submerged arc welding with high efficiency by filling the groove with cut wire, fine wires of the same chemical composition as submerged arc welding wire chopped to almost the same length as wire diameter.

Cut wire
A C h A D

Metal from wire Metal from cut wire

C E 0.74h 0.26h

n TYPE OF CUT WIRES Brand Name NITTETSU YK-C NITTETSU YK-D Typical Chemical Composition (%) C Si Mn P S Mo 0.11 0.13 0.01 0.01 0.01 1.43 0.013 0.015 1.87 0.010 0.014 Flux to be used (mesh) NITTETSU YF-15A (20D)

NITTETSU YK-CM 0.08

NITTETSU YF-15A (20D) NITTETSU NB-55E (12100) 1.67 0.012 0.014 0.51 NITTETSU YF-15B (20D)

CHARACTERISTICS
1. More than double amount of weld metal compared with conventional submerged arc welding is obtained and it is especially suitable for welding thick plates. 2. Heat affected zone of the base metal is small and consequently deterioration of toughness is limited. 3. Beautiful bead with large leg length is obtained in flat fillet welding and slag is easy to remove. 4. Hot temperature cracking can be prevented in the welding of high carbon steel since dilution rate of base metal is low. 5. Arc is stable and bead is beautiful even in high current welding.

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222

90 3.0 2.5 Cut Wire 2.0 Flux Wire YF15 (20 X D) YC (4.8) (6.4 8.0) YKC (1.0X1.0) 80 70 60 50

3.5

20%0% Reinforcement

9 8.5 8 7.5 7 6.5 6 5.5 5 1.5 1600A (8.0) 1.0 1400A (6.4) d c 1200A (6.4) g e i 1000A (4.8) 900A (4.8) 800A (4.8)

Fill the groove completely with cut wire

4.5

3.5

2.5

2 b 0.5 0.4 0.3 0.2 0.1

ro

ve

e gl An

1.5

Groove Cross Section Area A (cm2)

Cross Section Area Welded by Submerged Arc Welding Wire A (cm2)

0.5

0 16 18 20 22 24

a 26 28 30 0 10

h 20

f 30

j 40 50

10

12

14

Groove Depth d (mm)

Welding Speed (cm/min)

NOMOGRAPH TO SELECT WELDING CONDITIONS

223

14

ONE-SIDE WELDING PROCESS

One-side Welding Process to Shorten Welding Time Using Various Kinds of Backing Materials
Backing Materials and Flux NITTETSU SB-41 Welding Process Gas shield arc welding [Flux cored arc welding wires and Gas metal arc welding wires] Cake Backing Process Gas shield arc welding (Gas metal arc welding wires) Tape Backing Process Soft Backing Process Submerged arc welding

NITTETSU SB-30 NITTETSU SB-31 NITTETSU SB-51 Surface flux NITTETSU NSH-50 NITTETSU Flux Copper NITTETSU NSH-50M Backing Process NITTETSU NSH-55EM (FCuB Process) NITTETSU NSH-R Backing flux NITTETSU NSH-1RM

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NITTETSU SB-30/SB-31
Backing Material for Gas Metal Arc Welding Wire
NITTETSU SB-30 is a backing material for Cake Backing Process which uses a solid flux with a few sheets of glass tape adhered to the surface. NITTETSU SB-31 is a backing material for Tape Backing Process which uses a tape made of specially treated glass fiber. n SHAPE, CHARACTERISTICS AND WELDING WIRES Backing Materials NITTETSU SB-30
Both-side adhesive tape Length: 300,600mm
7

NITTETSU SB-31
50

Size and Shape

Glass tape Solid flux

Both-side adhesive tape Treated glass tape

1. A beautiful reverse bead 1. It can be used by cutting is assured since it has an to the welding length and, adequate fire resistance therefore, there are no and produces slag with joints and no waste. proper viscosity. 2. It is highly flexible and, 2. Adhesiveness to base metal therefore, adheres to any which is a weak point of bended plates. Characteristics solid backing material has 3. The disposal of backing been improved by the use of materials after welding is a few sheets of glass tape. easy and hygienic. 3. Excellent mechanical properties are obtained by the metallurgical reaction with weld metal. Recommended Wires NITTETSUYM-26, NITTETSUYM-28 (CO2) NITTETSUYM-28S (Ar+CO2)

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NITTETSU SB-41
Backing Material for Gas Shield Arc One-side Welding
NITTETSU SB-41 is a backing material having a structure of tile-like solid flux blocks which are stuck onto aluminium foil in succession.

Degassing hole Peel off paper

Solid flux

Aluminium foil with adhesive

Aluminium foil Solid flux

<Structure of NITTETSU SB-41>

<How to use NITTETSU SB-41>

n RECOMMENDED WELDING WIRES Flux cored arc welding wires Gas metal arc welding wires NITTETSU SF-1, NITTETSU SF-3, etc. NITTETSU YM-26, NITTETSU YM-28, etc.

APPLICATIONS
1. It is small and light and consequently is easily set up by sticking adhesive face of aluminium foil to steel plate. 2. It can be used by cutting to the desired length and bending up or down since solid fluxes are tile-like and flexible. 3. It can be used for uranami (sound penetration bead) welding with a wide range of welding conditions since solid fluxes have high fire resistance. 4. Inventory control is easy since it rarely absorb moisture and, therefore, redrying is not necessary.

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226

n SIZE AND SHAPE Width Length Type (Groove Depth Width) Standard A B GL 30600 (1.212) 26600 (1.514) 26600 (0.89) 30600 (1.212) Applicable Wire Flux Cored Wire Solid Wire General purpose General purpose General purpose General purpose
Joint

Shape

How to Use

Degassing hole
0 61 05 60
25 30 12

126
Aluminium foil with adhesive

The same as above With glass tape

Aluminium foil

The same as above

30600 (1.414)

Different plate thickness

0 61 005 6

100

9.5

30 8 1.5 12.5 8

Aluminium foil

30200R 30250R 30300R (1.414)

S B 41 ( R )

Circular Plates

300R

3090 17R (1.414)

L longitudinals

30 14 17R 90 30 Magmet champ

S B 41

200

S B 41

100 20

35

20350

Aluminum foil with adhesive

T joints

25

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SOFT BACKING SUBMERGED ARC WELDING PROCESS

Soft Backing Process is to carry out one-side submerged arc welding by fitting NITTETSU SB-51, portable and light backing material, to a steel plate using magnet clamps as shown in the figure. Welding is carried out by filling the groove with cut wires in order to minimize the influence of groove gap fluctuation onto the shape of reverse head.
Wire Flux Cut wire Base metal Glass tape Solid flux Magnet clamp

NITTETSU SB-51

APPLICATIONS
One-side welding where backing jigs cannot be used like welding of curved plates in shipbuilding and site welding of bridges.

CHARACTERISTICS
1. Glass tape assures excellent adhesiveness to base metal and an even reverse bead. 2. It can be attached by magnet clamps since little push-up strength is required. 3. An even reverse bead shape similar to other parts is obtained at joining parts of backing materials. 4. The concurrent use of cut wire makes it unsusceptible to the fluctuation of groove gap and assures high efficiency. n RECOMMENDED WELDING MATERIALS
Base metal Welding Process 1 layer welding Mild steel Flux NITTETSU YF-15A Wire NITTETSU Y-D Cute Wire

14

2 electrodes MultiL : NITTETSU Y-DL NITTETSU YK-C NITTETSU NSH-50M layer welding T : NITTETSU Y-DL 1 layer welding NITTETSU NB-55E NITTETSU Y-D NITTETSU YF-15A NITTETSU Y-D NITTETSU YK-C NITTETSU YK-D

490MPa high tensile strength steel

2 electrodes MultiL : NITTETSU Y-DL NITTETSU NSH-52 layer welding T : NITTETSU Y-DL

228

n TYPICAL WELDING CONDITIONS 1) ONE-LAYER WELDING (NITTETSU YB-100, NITTETSU YB-150)(AC) Plate Thickness mm 8 16 Groove Shape I 50V Wire Dia mm 4.8 6.4 Groove Gap mm 0 3 0 Cut Wire Current Height A mm 16 800 700 1100 Voltage V 32 32 36 Speed cm/min 45 42 30

2) MULTI-LAYER WELDING WITH TWO Plate Groove Wire ThickGeometry Layer Electrode Dia ness mm mm mm
50

ELECTRODES (AC) Cut Distance Wire Current Voltage Speed between Height A V cm/min Electrodes mm mm 16 1000 950 38 41 36 80

18
2

L T

4.8 6.4

n TYPICAL CHEMICAL COMPOSITION OF WELD METAL (%) C A B 0.16 0.16 Si 0.20 0.20 Mn P S Plate Base Metal Thickness mm 20 18 Welding Method 1 layer welding Flux NITTETSU NB-55E

1.15 0.017 0.003 K32D 1.15 0.017 0.003 K36D

2 electrodes, NITTETSU 2 layers NSH-50M welding

n TYPICAL MECHANICAL PROPERTIES OF WELD METAL Yield Point, MPa A B 400 390 Plate Tensile Elonga- Charpy 2 V-notch Base Strength, tion, at 0C, Thickness Metal MPa % J mm 560 530 27 28 120 60 K32D K36D 20 18 Welding Method 1 layer welding Flux NITTETSU NB-55E

2 electrodes, NITTETSU 2 layers NSH-50M welding

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NITTETSU FLUX COPPER BACKING SUBMERGED ARC WELDING PROCESS

NITTETSU Flux Copper Backing Process is a high efficiency automatic welding process to carry out one-side submerged arc welding by spreading backing flux (NITTETSU NSH-1R) to the thickness of a few millimeters on backing copper plates, as shown in the figure, and sticking the copper plate closely to the reverse surface of the groove using a pushing up device. High speed and high efficiency welding is achieved by using a pushing up device. High speed and high efficiency welding is achieved by using a systematized welding apparatus. Especially, NH-HISAW Process with 4 electrodes can increase welding speed as much as 2.5 times high as conventional submerged arc welding process.
Wire Surface ux

Steel plate Backing ux (NITTETSU NSH-1R) Backing copper plate Copper plate support Air hose Hose trough

APPLICATIONS
Welding of large plates for ships, bridges and structures.

CHARACTERISTICS
1. High current can be used since reverse bead height tends to be even due to the copper plate under backing flux layer and fluctuation of reverse bead shape is small. 2. Highly efficient and economic welding is possible by systematizing welding apparatus. 3. NITTETSU NSH-50, surface flux, can be used for both mild steel and 490MPa high tensile strength steel. n One-side SAW Welding Material

14

Base metal Mild Steel and 490MPa high tensile strength Steel 490MPa Grade E high tensile strength Steel

Wire NITTETSU Y-A NITTETSU Y-DL

Surface Flux NITTETSU NSH-50 NITTETSU NSH-50M

Backing Flux NITTETSU NSH-1R NITTETSU NSH-1RM NITTETSU NSH-1RM NITTETSU NSH-1RM

NITTETSU Y-DM3 NITTETSU NSH-55EM Y-DL NITTETSU NSH-55L

Low temperature Service NITTETSU Y-3NI Steel

230

n TYPICAL WELDING CONDITIONS (2~3 ELECTRODES)

Flux Plate Distance Backing Groove Wire Electrode Current Voltage Speed ThickBetween Flux Tilt ness Geometry Electrode Dia. cm/min Electrodes Height mm Angle A V mm mm mm mm

13
60

NITTETSU NSH-50 NITTETSU NSH-1R

16

20

50 3 50

25
45

32

L T L T L T1 T2 L T1 T2 L T1 T2 L T1 T2

4.8 6.4 4.8 6.4 4.8 6.4 6.4 4.8 6.4 6.4 4.8 6.4 6.4 4.8 6.4 6.4

15 0 15 0 15 0 5 15 0 5 15 0 5 15 0 5

1050 800 1050 850 1150 1050 700 1250 1000 850 1350 1150 950 1400 1150 950

38 42 38 42 38 42 45 36 42 45 36 42 48 36 42 48

54 50 65

30 30 30 120 30 120 30 120 30 120

4 4 4

60

55

44

Note: NITTETSU NSH-55 is used for three-electrode welding in principle.

n TYPICAL WELDING CONDITIONS (4 ELECTRODES, NH-HISAW PROCESS)

Flux Plate Distance Backing Groove Wire Electrode Current Voltage Speed Thick- Geometry Electrode Dia. Between Flux Tilt ness Electrodes Height cm/min mm Angle A V mm mm mm mm
60 3

13

16

50 3

50

20

50

25

L T1 T2 T3 L T1 T2 T3 L T1 T2 T3 L T1 T2 T3

4.8 6.4 6.4 6.4 4.8 6.4 6.4 6.4 4.8 6.4 6.4 6.4 4.8 6.4 6.4 6.4

15 0 5 10 15 0 5 10 15 0 5 10 15 0 5 10

1400 1100 650 650 1700 1300 750 700 1700 1400 750 750 1700 1400 1050 950

35 40 45 42 35 40 40 45 35 40 40 45 35 40 40 45

NITTETSU NSH-50 NITTETSU NSH-1R

150

30 200 30 30 200 30 30 200 30 30 200 30

150

100

14

90

231

n TYPICAL WELDING CONDITIONS (2~3 ELECTRODES)

Flux Plate Distance Backing Groove Wire Electrode Current Voltage Speed Thick- Geometry Electrode Dia. Between Flux Tilt ness Electrodes Height mm Angle A V cm/min mm mm mm mm

NITTETSU NSH-50M or NITTETSU NSH55ENM NITTETSU NSH-1RM

13
60

16

20

50 3 50

25
45

32

L T L T L T1 T2 L T1 T2 L T1 T2 L T1 T2

4.8 6.4 4.8 6.4 4.8 6.4 6.4 4.8 6.4 6.4 4.8 6.4 6.4 4.8 6.4 6.4

15 0 15 0 15 0 5 15 0 5 15 0 5 15 0 5

1050 800 1050 850 1150 1050 700 1250 1000 850 1350 1150 950 1400 1150 950

38 42 38 42 38 42 45 36 42 45 36 42 48 36 42 48

54 50 65

70 70 30 120 30 120 30 120 30 210

4 4 4

60

55

44

Note: NITTETSU NSH-55M is used for three-electrode welding in principle.

n TYPICAL WELDING CONDITIONS (4 ELECTRODES, NH-HISAW PROCESS)

Flux Plate Distance Backing Groove Wire Electrode Current Voltage Speed Thick- Geometry Electrode Dia. Between Flux Tilt ness Electrodes Height mm Angle A V cm/min mm mm mm mm
60 3

13

16

50 3

14

50

20

50

25

L T1 T2 T3 L T1 T2 T3 L T1 T2 T3 L T1 T2 T3

4.8 6.4 6.4 6.4 4.8 6.4 6.4 6.4 4.8 6.4 6.4 6.4 4.8 6.4 6.4 6.4

15 0 5 10 15 0 5 10 15 0 5 10 15 0 5 10

1400 1100 650 650 1700 1300 750 700 1700 1400 750 750 1700 1400 1050 950

35 40 45 42 35 40 40 45 35 40 40 45 35 40 40 45

NITTETSU NSH-50M NITTETSU NSH1RM

150

30 200 30 30 200 30 30 200 30 30 200 30

150

100

90

232

n TYPICAL CHEMICAL COMPOSITION OF WELD METAL (%) 1) NITTETSU NSH-50 NITTETSU Y-A/Y-A/Y-A C Si Mn P S Plate Base Thickness Metal mm KD 25 25 32 Welding Method Flux

A 0.12 0.34 1.35 0.018 0.009

B 0.12 0.40 1.50 0.014 0.008 K32D C 0.12 0.41 1.50 0.016 0.008 K32D

3 electrodes, one-side welding NITTETSU NSH-50 3 electrodes, one-side welding NITTETSU NSH-50 3 electrodes, one-side welding NITTETSU NSH-50

2) NITTETSU NSH-50 NITTETSU Y-A/Y-A/Y-A C A B C D 0.12 0.11 0.12 0.12 Si 0.42 0.39 0.44 0.45 Mn 1.45 1.50 1.65 1.62 P 0.017 0.018 0.019 0.018 S Plate Base Thickness Metal mm 20 32 20 32 Welding Method 3 electrodes, one-side welding 3 electrodes, one-side welding 3 electrodes, one-side welding 3 electrodes, one-side welding

0.006 KD 0.009 KD 0.008 K32D 0.009 K32D

3) NITTETSU NSH-50 NITTETSU Y-A/Y-A/Y-A/Y-A (NH-HISAW PROCESS) C A 0.13 Si 0.25 Mn 1.43 P 0.02 Plate Base Welding Thickness Metal Method mm 0.005 DH36 25 4 electrodes, one-side welding S

n TYPICAL CHEMICAL COMPOSITION OF WELD METAL (%) 1) NITTETSU NSH-50M NITTETSU Y-DL/Y-DL/Y-DL C 0.13 Si 0.23 Mn 1.17 P 0.018 S 0.004 Base Metal KD36 Plate Thickness Welding Method mm 3 electrodes, one-side welding 20

2) NITTETSU NSH-55EM NITTETSU Y-DM3/Y-DL/Y-DL C 0.09 Si 0.18 Mn 1.32 P 0.018 S 0.005 Base Metal KE40 Plate Thickness Welding Method mm 3 electrodes, one-side welding 20

14

3) TYPICAL CHEMICAL COMPOSITION OF WELD METAL (%) (NH-HISAW PROCESS) NITTETSU NSH-50M NITTETSU Y-DL/Y-DL/Y-DL/Y-DL C 0.12 Si 0.20 Mn 1.15 P 0.019 S 0.005 Base Metal KD36 Plate Thickness Welding Method mm 4 electrodes, one-side welding 20

233

n TYPICAL MECHANICAL PROPERTIES OF WELD METAL 1) NITTETSU NSH-50 NITTETSU Y-A/Y-A/Y-A Yield Point, MPa A B C 390 410 420 Tensile Elonga- Charpy 2 V-notch, Plate Base J Strength, tion, Thickness Metal MPa % 10C 0C mm 500 550 550 30 31 30 89 72 98 KD K32D K32D 25 25 32 Welding Method Flux

3 electrodes, NSH-50 one-side welding 3 electrodes, NSH-50 one-side welding 3 electrodes, NSH-50 one-side welding

2) NITTETSU NSH-50 NITTETSU Y-A/Y-A/Y-A Yield Point, MPa 390 380 450 430 Tensile Elon- Charpy 2 V-notch Strength, gation, at 0C, MPa % J 510 30 77 510 31 65 610 29 69 600 29 64 Plate Base Thickness Metal mm KD 20 KD 32 K32D 20 K32D 32 Welding Method 3 electrodes, one-side welding 3 electrodes, one-side welding 3 electrodes, one-side welding 3 electrodes, one-side welding

A B C D

3) NITTETSU NSH-50 NITTETSU Y-A/Y-A/Y-A/Y-A (NH-HISAW PROCESS) Yield Point, MPa A 366 Tensile Strength, MPa 532 Elongation, % 29 Charpy 2 V-notch at 0C, J 125 Base Metal DH36 Plate Thickness mm 25

n TYPICAL MECHANICAL PROPERTIES OF WELD METAL 1) NITTETSU NSH-50M NITTETSU Y-DL/Y-DL/Y-DL Yield Point, MPa 460 Tensile Elonga- Charpy 2 V-notch Strength, tion, at 0C, MPa % J 550 27 135 Base Metal KD36 Plate Thickness Welding Method mm 3 electrodes, one-side welding 20

2) NITTETSU NSH-55E NITTETSU Y-DM3/Y-DL/Y-DL

14

Yield Point, MPa 490

Tensile Elonga- Charpy 2 V-notch Base Strength, tion, at 0C, Metal MPa % J 570 25 120 KE40

Plate Thickness Welding Method mm 3 electrodes, one-side welding 20

3) TYPICAL MECHANICAL PROPERTIES OF WELD METAL (NH-HISAW PROCESS) Yield Point, MPa 470 Tensile Elonga- Charpy 2 V-notch Strength, tion, at 0C, MPa % J 550 26 120 Base Metal KD36 Plate Thickness Welding Method mm 4 electrodes, one-side welding 20

234