Submerged Arc Welding Advantages

To define arc welding first, it is a process wherein, two pieces of metal are welded to each other with the help of an electric arc, which is formed by a power supply which could be a direct or alternating current. The arc gets generated between an electrode and the work pieces. And one of this type of welding is what we are discussing here; the submerged arc welding (SAW). It is called so because the arc zone, the end of the electrode and the molted weld are kept hidden, and buried under a blanket of granular fusible flux. This is to protect them against atmospheric contamination.

SAW can be performed automatically, or with the help of manual labor. Some companies use semi-automatic SAW guns to get the job done. Although, SAW can work on complete automation, people generally do not opt for this choice. Most SAW jobs are done in a straight line, and the use of robots would be more needful when the work involves complex shapes. The rest of the article will take you through the benefits of submerged arc welding (SAW), and its applications in various fields.

How is SAW Advantageous?

• The process of arc welding results in spatter and spark, and at the same time, it generates intense ultraviolet radiation, and fumes. Such factors are avoided in a SAW process as the molten metal is completely covered by the thick layer of flux thus, making it environmentally friendly. Also, the suppression of radiation and fumes makes the SAW welding safer than other types of welding. The operators supervising the welding do not have to wear protective clothing, but instead, wear regular shop clothes.
• Since this welding works on electricity, it does not need to be applied with pressure.
• Because of the high magnitude of heat generated in this process, it is well suited for welding thick sections.
• SAW is especially known for its high metal deposition rates. And owing to this property, the welding offers deep penetration into the weld. Submerged arc welding with cored wires results in better deposition rates, unlike when solid wires are used.
• Again, because immense amount of heat gets concentrated, the process can be made to accelerate. A speed of up to 5 m/min can be achieved.
• The end product of the welding, which is the deposited weld metal, is imparted with better quality in uniformity, ductility, resistance to corrosion, and with higher endurance. Also, weld shapes have a neat appearance and display better smoothness.
• One of the biggest problems in welding processes is weld distortion. It occurs as a result of expansion and contraction of the weld metal and adjacent base metal. However, since SAW employs higher concentration of heat, and rapid welding, it is advantageous in reducing such distortion considerably.
• People can make use of this welding process both indoors and outdoors. Even in relatively windy areas, the SAW fits the bill for carrying out welding jobs.
• SAW is more beneficial for companies with multiple plant locations.

Applications of SAW

• The process is suitable for welding low alloy steel that scores low on being tensile.
• It is widely used in construction of rail road, boilers, and equipment used in moving earth. Fabrication of cranes, support beams for bridges, and lowest support for railway coaches and locomotives also commonly employ SAW.

To conclude with one last point, the fusible flux that is used in SAW remains solid granular throughout the submerged arc welding process thus, 50-90% of it can be reused.