1.

INTRODUCTION OF SUBMERGED ARC WELDING

1.1.1

History

The first patent on the submerged-arc welding (SAW) process was taken out in 1935 and covered an electric arc beneath a bed of granulated flux. Developed by the E O Paton Electric Welding Institute, Russia, during the Second World War, SAW's most famous application was on the T34 tank.

1.1.2

Process features

Similar to MIG welding, SAW involves formation of an arc between a continuously-fed bare wire electrode and the workpiece. The process uses a flux to generate protective gases and slag, and to add alloying elements to the weld pool. A shielding gas is not required. Prior to welding, a thin layer of flux powder is placed on the workpiece surface. The arc moves along the joint line and as it does so, excess flux is recycled via a hopper. Remaining fused slag layers can be easily removed after welding. As the arc is completely covered by the flux layer, heat loss is extremely low. This produces a thermal efficiency as high as 60% (compared with 25% for manual metal arc). There is no visible arc light, welding is spatter-free and there is no need for fume extraction.

1.1.3

Operating characteristics

SAW is usually operated as a fully-mechanised or automatic process, but it can be semi-automatic. Welding parameters: current, arc voltage and travel speed all affect bead shape, depth of penetration and chemical composition of the deposited weld metal. Because the operator cannot see the weld pool, greater reliance must be placed on parameter settings. 1.1.4 Process variants

According to material thickness, joint type and size of component, varying the following can increase deposition rate and improve bead shape. 1.1.5 Wire

SAW is normally operated with a single wire on either AC or DC current. Common variants are:

twin wire multiple wire (tandem or triple) single wire with hot or cold wire addition metal powder addition tubular wire

All contribute to improved productivity through a marked increase in weld metal deposition rates and/or travel speeds. A narrow gap process variant is also established, which utilises a two or three bead per layer deposition technique.

1.1.6

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. The flux is specially formulated to be compatible with a given electrode wire type so that the combination of flux and wire yields desired mechanical properties. All fluxes react with the weld pool to produce the weld metal chemical composition and mechanical properties. It is common practice to refer to fluxes as 'active' if they add manganese and silicon to the weld, the amount of manganese and silicon added is influenced by the arc voltage and the welding current level. The the main types of flux for SAW are:
I.

Bonded fluxes - produced by drying the ingredients, then bonding them with a low melting point compound such as a sodium silicate. Most bonded fluxes contain metallic deoxidisers which help to prevent weld porosity. These fluxes are effective over rust and mill scale. 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.

II.

1.1.7

Applications

SAW is ideally suited for longitudinal and circumferential butt and fillet welds. However, because of high fluidity of the weld pool, molten slag and loose flux layer, welding is generally carried out on butt joints in the flat position and fillet joints in both the flat and horizontal-vertical positions. For circumferential joints, the workpiece is rotated under a fixed welding head with welding taking place in the flat position. Depending on material thickness, either single-pass, two-pass or multipass weld procedures can be carried out. There is virtually no restriction on the material thickness, provided a suitable joint preparation is adopted. Most commonly welded materials are carbon-manganese steels, low alloy steels and stainless steels, although the process is capable of welding some non-ferrous materials with judicious choice of electrode filler wire and flux combinations. 3

1.2 EQUIPMENT

Cheaper Player Ruler Hammer Wire brush Gloves

1.3 WORK ACTIVITIES

Make two straight and parallel arc line on the metal plat.

a. Before doing this project, you must make sure that the condition and setting of the machine is correct by observe the pattern of arc. b. After that, you must clean the surface of the metal plat to avoid the dusk affect the pattern of the arc during welding session. c. Next, you have to place the plat on the table of the machine and perpendicular to the nozzle that flow out the wire and flux. d. Before start the welding, you must make sure that the flux flow smoothly on the plat. e. Switch on the power and speed control at the same time, to make sure that movement of the nozzle is in the right way. f. When the nozzle reach the end point, you must rapid switch off the power and also switch off the speed control. g. Then, you must use glove to protect your hand because this metal are very hot after the process. h. Take the player and the cheaper to take off the flux that is stick together with the plat. i. The process from a to h is repeat to make the second arc line.

Join two metal plat by using Submerged Arc Welding(SAW)

a. Before doing this project, you must make sure that the condition and setting of the machine is correct by observe the pattern of arc. b. After that, you must clean the surface of the metal plat to avoid the dusk affect the pattern of the arc during welding session. c. Next, you must welding at both end of the plat that join by using conventional arc welding to make sure that both plat are more stable during welding session. d. Next, you have to place the plat on the table of the machine and perpendicular to the nozzle that flow out the wire and flux. e. Before start the welding, you must make sure that the flux flow smoothly on the plat. f. Switch on the power and at the same time, you must switch the speed control that move the nozzle left and right on the table. g. When the nozzle reach the end point, you must rapid switch off the power and also switch off the speed control. h. Then, you must use glove to protect your hand because this metal are very hot after the process. i. Take the player and the cheaper to take off the flux that is stick together with the plat.

TIPS IF YOU WANT THE PATTERN OF THE ARC MORE PERFECT AND GET THE GREAT RESULT, YOU MUST PUT THE WORKPIECE BETWEEN THE RECYCLE PLAT AND MAKE SURE YOU START AND FINISH THE PROCESS ON THE RECYCLE PLAT YO AVIOD THE PROBLEM WHEN YOU START AND FINISH THE WELDING PROCESS.

1.4 OBSERVATION

PROJECT 1

PROJECT 2

1.5 DISCUSSION
Advantages

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

Flat or horizontal position welding only. Care required to preserve correct electrode alignment, as electrode. Tip and weld pool are underneath solid flux cover. Flux will run out quickly and than take time to fill it back.

1.6 COMMENTS AND SUGGESTIONS

This machine is easy to run,anyone can handle it safely but it is hard to get the best setting for the best welding. This machine must be add for student try their best work and project. To get more knowledge,student must build a final project by use the machine with different style and different setting.After that,compare it with friends.

1.7 CONCLUSION
In conclusion, at the end of the period, we can learn how to handle submerged arc welding(SAW) and the function of the machine. We also get the valuable experience during this workshop. The instructor are very helpful and ready to share the experience with student. We also know the advantages and disadvantages of the machine and the purpose of the machine. 7