Submerged Arc Welding

1. SAW Principles
 Advantages
• High Deposition Rates
• Fast Welding Speeds
• Typically Deep
Penetration
• High Operator Appeal
• High Operating Factor
• High Quality Welds
• Low Hydrogen Welds
 Limitations
• Portability (External
Shielding Flux Required)
• Downhand welding only
(external shielding flux is
susceptible to gravity)
• Moderate Operator Skill
Is Necessary
• Tight Fit-Up Required
• Abrasive Nature of Flux on
Machinery
• Housekeeping and Storage
of Flux
• Slag
 Application
• structural shapes
• longitudinal seam of larger diameter pipe
• the manufacture of machine components for all
types of heavy industry
• the manufacture of vessels and tanks for pressure
and storage use
• shipbuilding industry fabricating sub-assemblies
• surfacing and buildup work, maintenance, and
repai
 2. Welding Variables - Current, Voltage

Effect of Welding Current

Effect of arc voltage

27V 34V 45V

J. Ray McDermott
Effect of arc voltage on bead
 3. Welding Variables – Electrode Stickout, Wire Diameter

Effect of Electrical Stickout

Effect of Wire
Diameter

J. Ray McDermott
 4. Welding Variable – Electrode Angle

Effect of electrode angle on butt welds.

Trailing Vertical Leadin

g

J. Ray McDermott
 5. Welding Variable – Electrode Angle

Effect of electrode angle on Fillet Welds

40
30

Equal leg length Deepest

penetration.
J. Ray McDermott
 6. SAW - Single Process, Electrode Stickout

120o

J. Ray McDermott
 2 Equipment Setup
• Best Results, CV Power Source with SAW Mode
• Wire Electrode with External Shielding Flux
• DCEP (DC+) Polarity
• DCEN (DC-) Polarity
• AC
• Constant Voltage (CV)
Power Source
• Constant Speed Wire
Feeder
and Control
• A Travel Carriage,
Tractor or Manipulator
• Contact Nozzle
Assembly
• Consumable Wire
Electrode and
Shielding Flux
 Power source DC 1000
Output Control Knob
Weld Mode
Switch

Ammeter On/Off Power .

Switch

Voltmeter Local/Remote .
Switch

Wire Feeder
Voltmeter Switch Terminal Strip

Negative Output Positive Output

Terminals Terminals
Wire feeder LT-7
Wire Feeder LT-7
Track vs Standard Model
Electrode Cable
Connection

Flux Tube & Flux

Contact Tip Tube Tip

Flux Housing

Flux Cone
Retaining Nut
 6. Submerged Arc Processes

• Single Arc

• Tiny Twin Arc

• Tandem Arc

J. Ray McDermott
 7. Single Arc
• Simplest
• Automatic or Semiautomatic
• Polarity : DC +, DC - or AC

J. Ray McDermott
Arc Blow
 8. Equipment - Contact Nozzles
SAW - Automatic Single Arc
K148 K231

J. Ray McDermott
 9. Tiny Twin Arc
• Two Wires - One Power Source,
One Wire Drive and One Control
• Polarity : DC + or DC -
• Wire Sizes: 1/16”, 5/64” and
3/32”

J. Ray McDermott
 10. Equipment - Contact Nozzles

SAW - Automatic Twin Arc

K129

J. Ray McDermott
 11. Tandem Arc
• Two Wires - Two Power Sources
• Lead Wire is DC or AC
• Trail Wire is AC
• Used with Travel Carriage, Tractor

J. Ray McDermott
 12. Wire feeder

• Tractor Runs on Track

or Work piece Itself
• Mobile for Field Work
(Ships, Decking, Tanks,
etc.)
• Portable
• One Operator

J. Ray McDermott
 10. Circumferential Weld

J. Ray McDermott
 11. Circumferential Weld
Centre Displacement Effect

J. Ray McDermott
Electrode & Flux