Submerged Arc Welding

Submerged Arc Welding (SAW) is a common arc welding process which is used to join thick and heavy sections. The basic characteristics of this process are high deposition rate, ability to weld thick sections with ease and longer weld runs. The study of weld bead geometry is important, as it determine the stress carrying capacity of a weld. For the same reason, this paper highlights the analysis and study of process parameters: arc Voltage, welding current, travel speed and electrode extension, on the bead geometry response such as, bead height, bead width and bead penetration. Design Expert 8.0 with 4 factors, 5 levels, rotatable Central Composite Design. was used to develop relationship for predicting weld bead geometry, which enables to quantify the direct and interaction effects. Mathematical models prepared for the submerged arc welding of 16mm thick mild steel by using response surface methodology which co relate the process variables with the bead geometry characteristics then ...

The relationships between the compositions of a submerged arc welding bonded flux with the structure and properties are evaluated. Evaluations about the particularities of the flux structure are made based on the relationships O: Si and O:(Si+ Al). Analysing the obtained ...

Heat source models are mathematical expressions that represent the generation term in the fundamental heat transfer equation. Investigators have successfully demonstrated different heat source models for single-wire welding. The present investigation estimates the double ellipsoidal heat source model parameters for twin-wire application. The heat source model parameters have been estimated for varying set of welding conditions. It has been found that the heat source model parameters for twin-wire welding are different from the single-wire welding. Moreover, the heat source model parameters also depend upon process parameters. Effects of welding current, electrode polarity and wire diameter on the size of heat source model have been presented. Flux consumption is also found to play a significant role in deciding the heat source model parameters.

Like heat treatment processes, manufacturing methods that require heat input, such as welding process, can cause changes in material properties. This study aims to investigate the effect of carbon content and welding process on the hardness of welded carbon steels. For this purpose, samples of ultra-low carbon interstitial free, low carbon and medium carbon steels that have similar composition but different carbon content are used. All samples are heat treated to remove residual stresses remained during the manufacturing processes. Automated submerged arc technique is used to create a weld beam on plate despite a joining process. Rockwell B scale is used for hardness measurements. Results prove that steel carbon content and welding process have an effect on hardness around the weld beam.

The present study has been carried out to investigate the coarse-grained heat-affected zone (CGHAZ) microstructure and crack tip opening displacement (CTOD) toughness of grade StE 355 Ti-microalloyed offshore steels. Three parent plates (40-mm thick) were studied, two of which had Ti microalloying with either Nb + V or Nb also present. As a third steel, conventional StE 355 steel without Ti addition was welded for comparison purposes. Multipass tandem submerged arc weld (SAW) and manual metal arc weld (SMAW) welds were produced. Different heat-affected zone (HAZ) microstructures were simulated to ascertain the detrimental effect of welding on toughness. All HAZ microstructures were examined using optical and electron microscopy. It can be concluded that Ti addition with appropriate steel processing, which disperses fine TiN precipitates uniformly, with a fine balance of other microalloying elements and with a Ti/N weight ratio of about 2.2, is beneficial for HAZ properties of StE 355 grade steel.

One of the most important weld quality characteristics related to the strength of the weld is the hardness of melted zone (HMZ) that is affected by different input parameters in the submerged arc welding process. In recent years, expensive nanomaterials have been effectively used in improving the quality of products in various fields. Keeping this in mind, it was therefore, decided to use a cost-effective approach to extract expensive and poisonous vanadium, from the hazardous wastewater collected from the Bistoon thermal power plant in Kermanshah province in Iran, and then introduce it into the weld pool via the cheap boehmite nanoparticles to investigate its impact on the HMZ. A five-level five-factor rotatable central composite design was then employed for collecting data in modeling of the HMZ as a function of arc voltage (V), welding current (I), stick-out (N), welding speed (S), and thickness of boehmite nanoparticles surface adsorbed with vanadium (F) coated on low-carbon steel plates (St37) prior to actual welding. The results showed that the addition of boehmite nanoparticles surface adsorbed with vanadium increased the HMZ by 13 % approximately.

The submerged arc welding machine broadly use in the industries for the material joining process. Penetration, bead width, reinforcement, tensile strength, impact strength, and hardness are some output parameters that define the quality of the weld. Arc current, feed rate, travel speed, electrode diameter, voltage, stick out, and angle of the electrode are input parameters of the SAW process. Many researchers optimize process parameters according to their requirements. This paper covers the effect of different input parameters on weld quality from different research papers. In this paper, study the effect of microstructure, heat-affected zone, and heat input on the weld joint. After analysis of all research papers, observes how parameters affect weld bead geometry and mechanical properties. And how to weld quality can be controlled in the SAW process.

Bu çalışmada, Ramor 500 zırh çeliği çifti tozaltı kaynak yöntemi ile birleştirilmiştir. Birleştirme işleminde Cr, Ni ve Mn esaslı östenitik ilave tel kullanılmıştır. Kaynak işlemi sonrası numunelere radyografik muayene yapılmıştır. Kaynak dikiş geometrileri ölçülmüş ve mikrosertlik dağılımları incelenmiştir. Yapılan çalışma sonucunda, kaynaklı numunelerin birleşme noktalarında gerilim arttıkça dikiş geometri form ölçüleri artmıştır. Birleştirilen bu numunelerin çekme dayanımı testleri ile birleşme mukavemetleri, X–Ray kırınımı yöntemi ile radyografi testleri incelenmiştir. Gerilime bağlı olarak mikrosertlik değerleri birbirine yakın sonuçlar göstermiştir. Sertliğin ITAB bölgesinde azaldığı ve kaynak metalinde yüksek artış gösterdiği gözlemlenmiştir.

Öz Ramor 500 zırh çeliği; 2-30 mm kalınlıklara sahip, 505-590 HV sertliklerde bulunan yüksek mukavemetli bir balistik koruma çeliği olarak sınıflandırılır. Çalışmada, Ramor 500 zırh çeliği malzeme çifti tozaltı kaynak yöntemiyle birleştirilmiştir. Kaynak işleminde kullanılan östenitik ilave tel Cr, Ni ve Mn esaslıdır. Birleştirme işleminden sonra numuneler tahribatsız muayene yöntemlerinden biri olan, X-Ray kırınımı yöntemi ile radyografik muayene uygulanmıştır. Kaynak bölgesinin dikiş geometrileri ölçülmüş ve mikrosertlik analizleri yapılmıştır. Kaynaklı numunelerin çekme dayanımı testleri ile mekanik davranışları ve kırık yüzeylerin SEM-XRD analizleri ile kırılma tipi ve bileşik oluşumları incelenmiştir. Çalışma sonucunda, kaynak tel ilerleme hızı arttıkça kaynak dikiş formunun genişliği ve yüksekliği azalmakta ve çekme mukavemetleri ile % gerinim artmaktadır. Birleşme ara yüzeydeki kırılma tipi, SEM-XRD sonuçlarından sünek kırılma olarak gözlemlenmiştir. Kaynak tel ilerleme hızına bağlı olarak mikrosertlik ölçümleri birbirine benzer sonuçlar vermiştir. Sertlik değerlerinin, ana malzeme ve ITAB'da azaldığı, kaynak metalinde ise yüksek artış gözlendiği incelenmiştir. Anahtar kelimeler: Kaynak metali, Nüfuziyet Dengesi, Ramor 500, Tel İlerleme hızı, Tozaltı Kaynağı Abstract The Ramor 500 armor steel is classified as a high strength ballistic protection steel with 2-30 mm thicknesses and 505-590 HV hardnesses. In the study, the Ramor 500 armor steel material pair was combined with a submerged welding method. The austenitic additive wire used in the welding process is based on Cr, Ni and Mn. After the joining process, the specimens were subjected to radiographic examination by X-ray diffraction method, which is one of the non-destructive examination methods. Sewing geometry of weld zone was measured and micro hardness analysis was done. Tensile strength tests of welded specimens investigated the mechanical behaviors and fracture type and compound formations by SEM-XRD analysis of fractured surfaces. As the welding wire advance speed increases, the width and height of the weld seam form decreases and the tensile strength and % strain increase. The fracture type at the interface was observed as ductile fracture from the SEM-XRD results. Microhardness measurements gave similar results depending on the feed rate of the welding wire. It has been investigated that hardness values decrease in main material and ITAB and increase in weld metal is observed.

Bead-on-plate submerged arc welding was conducted on St37 steel by manufactured Cr, Mo, and Cr-Mo active basic fluxes produced via the unfused bonded method. The base metal heat-affected zone and weld metal (WM) microstructures were identified and characterized by optical microscopy and scanning electron microscopy. Furthermore, each element's recovery rate (η) and slag factor (α) determine the amount of element transferred from flux into WM. Then, the ferrite morphologies volume fraction of WMs was measured. Moreover, the chemical analysis of slag and inclusions was evaluated by point scan energy-dispersive X-ray spectroscopy and extensively discussed. The number density and size of the inclusions as well as their effects on the acicular ferrite (AF) formation were also elaborated. Then, the WMs' longitudinal tensile strength and Vickers hardness (HV) were measured. Finally, the Charpy V-notch test was conducted to determine the impact toughness; the fracture surfaces were investigated, as well.

Bead-on-plate submerged arc welding was performed on the AISI 4135 heat-treatable low-alloy (HTLA) steel using S2 welding wire and granular Cr-Mo basic flux. The Cr-Mo active flux was produced by the bonded-un-fused method. The alloying elements were introduced into the weld metal by active flux. Two methods were introduced for calculating the recovery rate (η) of the alloying elements. Moreover, by defining the slag factor (α) of the process and η of the alloying elements, the amount of a specific element transferred from flux into WM was calculated by the proposed equation. Likewise, microstructure evolutions, inclusions characteristics, longitudinal tensile, indentation, and CVN impact tests were performed and thoroughly investigated; fracture mechanisms of all WMs were also identified.

Bu çalışmada, Ramor 500 zırh çeliği çifti tozaltı kaynak yöntemi ile birleştirilmiştir. Birleştirme işleminde Cr, Ni ve Mn esaslı östenitik ilave tel kullanılmıştır. Kaynak işlemi sonrası numunelere radyografik muayene yapılmıştır. Kaynak dikiş geometrileri ölçülmüş ve mikrosertlik dağılımları incelenmiştir. Yapılan çalışma sonucunda, kaynaklı numunelerin birleşme noktalarında kaynak tel ilerleme hızı arttıkça dikiş geometri form ölçüleri azalmıştır. Birleştirilen bu numunelerin çekme dayanımı testleri ile birleşme mukavemetleri, X–Ray kırınımı yöntemi ile radyografi testleri incelenmiştir. Kaynak tel ilerleme hızına bağlı olarak mikrosertlik değerleri birbirine yakın sonuçlar göstermiştir. Sertliğin ITAB bölgesinde azaldığı ve kaynak metalinde yüksek artış gösterdiği gözlemlenmiştir.

Bu çalışmada, Ramor 500 zırh çeliği çifti tozaltı kaynak yöntemi ile birleştirilmiştir. Birleştirme işleminde Cr, Ni ve Mn esaslı östenitik ilave tel kullanılmıştır. Kaynak işlemi sonrası numunelere radyografik muayene yapılmıştır. Kaynak dikiş geometrileri ölçülmüş ve mikrosertlik dağılımları incelenmiştir. Yapılan çalışma sonucunda, kaynaklı numunelerin birleşme noktalarında kaynak tel ilerleme hızı arttıkça dikiş geometri form ölçüleri azalmış, kaynak gerilimi arttıkça kaynak dikiş geometrileri artmıştır. Kaynak tel ilerleme hızına ve kaynak gerilimine bağlı olarak mikrosertlik değerleri birbirine yakın sonuçlar göstermiştir. Sertliğin ITAB bölgesinde azaldığı ve kaynak metalinde yüksek artış gösterdiği gözlemlenmiştir.

The fatigue crack propagation rate (FCPR) in 316L austenitic stainless steel (ASS) and its weldments was investigated, at two loading amplitudes, 7 and 8.5 kN, under tension-tension mode. Two welding techniques, submerged arc welding (SAW) and manual arc welding (MAW), have been used. Magnetic δ-ferrite, depending upon Ni and Cr content in the metal, in the weld zone upon solidification

Submerged arc weldments of HY-100 steel prepared under standard conditions with five commercially available fluxes were analyzed to discern a basis for the variation in mechanical properties associated with different flux use. The variations in flux chemistry resulted in alloyed weldments with diverse weld metal mechanical properties as evident by Charpy impact, tensile, dynamic tear, and microhardness tests. The microstructures and macrostructures were examined using optical and electron microscopy in order to determine the basis for the variations in strength and toughness. Scanning electron microscope and energy dispersive x-ray experiments were performed to determine the size, type, distribution and volume fraction of the non-metallic inclusions in the weld metal. Inclusion characterization revealed that the role of the flux in alloying had a more significant effect on the strength and toughness than did the presence of specific inclusions.

In arc welding the heat flow from the tip of electrode to the base metal. The heat transfer rate is generally based on the work material, weld material, welding process, inert gases etc. The heat transfer rate and rate of cooling in welding can directly controls microstructure and mechanical properties of welded region and base metal. The proposed study going to carry out on multipass submerged arc welding for varying heat input. The one dimensional, two dimensional and three dimensional heat flow equation will be used for the total heat transfer rate in submerged arc welding. The corresponding mechanical properties hardness c-v-n test results tensile strength of welded joint will be studied. This process is use full in joining thick section of components used in various industries. Besides joining SAW can also be used for surface applications. Heat affected zone produced in within the base metal as a result of tremendous heat of arc is of big concern as it affects the performance of welded surfaced structure in service due to metallurgical changes in the affected region. The various changes in the metal can be analyzed by heat transfer rate. The various sub zones in the microstructure were observed in HAZ of SAE weld of partially transformed. The main purpose of proposed work is to investigate and correlate the study of heat transfer rate on multipass submerged arc welding.

Studies on temperature distribution during welding are very important because this may pave the way for application of microstructure modeling, thermal stress analysis, residual stress/distribution and welding process simulation. An attempt has been made in this paper to predict of temperature variation of entire plates during welding and after welding through an analytical solution is derived from the transient multi dimensional heat conduction of infinite plate to finite thickness. The heat input that is applied on the plate is exactly same amount of heat lost for electric arc is assumed to be a moving double central conicoidal heat source with Gaussian distribution for Submerged Arc Welding process. The prediction was compared with experimental results with generally good agreement.

The article presents the tests performed to determine the operating parameters and welding conditions for the S355JR structural steel using the Submerged Arc Welding (SAW) method. The tests were carried out on samples made of S355JR steel after welding performed in accordance with the PN-EN 15614 standard. The work analyzed the depth of penetration of the welding arc depending on various welding parameters of the tested samples. For the obtained results linear energy was calculated for the given welding parameters.

A neutral flux and four different wires were used to produce all weld metal submerged-arc multipass welds. Impact Charpy V transition curves were obtained from two testing series, each with a different notch position along the welded joint. The results show that, according to the notch position, distinct fractions of weld metal columnar and reheated regions are present at the notch tip. Impact toughness of the weld metal with predominance of reheated regions is always superior to that with predominance of columnar region. Modification of some of the ASME II Part C standards relating to the specification of welding consumables is recommended for improved consistency with ASME VIII code for boiler and pressure vessel fabrication.

Fusion welding is one of the most common techniques for joining materials in manufacturing. Due to the increased application of this welding process and the demand for higher quality welding deposits, such welding processes are suitable for improvement of their instrumentation and control. Any improvement to control technique will have a positive effect on welding quality and productivity. Some of