Cladding Processes

A PROJECT REPORT SUBMITTED BY

Mr. Jemish Kalathiya EN No: 166490355057
Mr. Menil Akbari EN No: 166490355502
Mr. Mehul Makwana EN No: 166490355536
Mr. Himanshu Borisa EN No: 166490355505

UNDER THE GUIDANCE OF

Mr. Rohan A. Mehta (Industrial guide)
Prof. Bhavin K. Gandhi (Institute guide)

UNDERGRADUATE STUDENT,
FABRICATION TECHNOLOGY DEPARTMENT

SIR BHAVSINHJI POLYTECHNIC INSTITUTE,

BHAVNAGAR.

GUJARAT TECHNOLOGICAL UNIVERSITY, AHEMBDABAD.

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 GUJRAT TECHNOLIGICAL UNIVERSITY
649: SIR BHAVSINHJI POLYTECHNIC INSTITUTE, BHAVNAGAR
55: DEPARTMENT OF FABRICATION TECHNOLOGY

CERTIFICATE for submission of IDP FOR 6 SEM Diploma in Fabrication Technology

This is to certify that this industry defined project-1(semester VI) entitled CLADDING PROCESSES
has been carried by

Mr. Jemish Kalathiya EN No: 166490355057

Mr. Menil Akbari EN No: 166490355502
Mr. Mehul Makwana EN No: 166490355536
Mr. Himanshu Borisa EN No: 166490355505
Has been carried out under my supervision and guidance.

Place: L & T HAZIRA, SURAT

Date:

(Sign.) (Sign.)
INDUSTRIAL GUIDE INSTITUTE GUIDE
Name of guide: Rohan A. Mehta Bhavin K. Gandhi
Designation: In charge HEAD OF DEPARTMENT
Department: HFS-4B Department of Fabrication Tech.
Name & place of organization: Sir Bhavsinhji Polytechnic Institute
L&T HED, SURAT BHAVNAGAR (GUJARAT)

(Prof. Bhavin K. Gandhi)

HEAD OF DEPARTMENT
Department of fabrication tech.
Sir Bhavsinhji polytechnic institute,
BHAVNAGAR (GUJARAT)

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 Page
SR no. Description
No.

4
1 ABOUT COMPANY
5
2 INTRODUCTION
5
3 WHAT IS CLADDING
7
4 PURPOSE OF CLADDING
8
5 WELD CLADDING PROCESS
9
6 ELECTRO SLAG STRIP CLADDING
47
7 SUBMERGE ARC STRIP CLADDING
50
8 FLUX CORED ARC WELDING
52
9 GAS TUNGTSTEN ARC WELDING
54
10 SUBMERGE ARC WELDING
55
11 DEPOSITION RATE OF OVERLAY PROCESS
56
12 COST ANNALISIS FOR DIFFERENT PROCESS

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 1. About Company

 Larsen & Toubro originated from a company founded in 1938

in Mumbai by two Danish engineers, Henning Holck-Larsen
and Soren Kristian Toubro.
 L&T Heavy Engineering manufactures and supplies custom
designed equipment & critical piping to process industries
such as fertilizer, chemical, refinery, petrochemical, and oil &
gas, as well as to sectors such as thermal & nuclear power,
aerospace and defense.
 Hazira Manufacturing Complex (HZMC) is L&T’s state-of-the-
art manufacturing facility located on the banks of River Tapi
near the Arabian sea (about 16 km away from Surat, Gujarat).
The facility spreads over more than 750 acres of land with a
1.6 km long water front facility. It employs more than 5000
people directly and more than 12,500 people indirectly.

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 2. Introduction

 A clad material is a composite metal containing two or more

layer that has been bonded together.
 Cladding is the method by which coating (layer of another
material) become an integral part of base metal.
 The base metal gets sandwiched between piece of the coating
metal.
 Cladding may be done one or both surface of the base metal.
However, two layer combinations are most common.
 In cladding, the surface coating exceeds about 3% of the total
mass of the base metal.
3. What is cladding
 One or more layers of corrosion resistant weld metal is
deposited on CS / LAS base material

Non Corrosive SS Clad

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 CS / LAS Base Material

Base material Clad material

-CS
-LAS 304L
304
321
347
309 SS
310
316L
316
317L
317
Copper
Aluminum

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 4. Purpose of cladding

 To obtain the properties of the cladding in the base metal at

lower cost.
 To obtain a combination of properties not available in either
metal alone.
For example, in copper- clad steel wire. Copper exterior provide
high electrical conductivity and good corrosion resistance which
steel core provides high tensile strength.

Available forms: -
1. strip
2. sheet
3. foil
4. plate
5. wire
6. rod, and
7. tube from

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 5. Weld Cladding Process

o Different processes are being employed in overlaying like:

 ESSC – Electro Slag Strip Cladding. Applicable to large inside

area of Shell, D/E, Cone, & TS
 SASC – Submerged Arc Strip Cladding Applicable to large inside
area of Shell, D/E, Cone, TS
 FCAW – Flux Cored Arc Welding. Applicable to Flange face,
Small size T/S, Pipes of smaller diameter,
 MIG – Metal Inert Gas Welding. Applicable to Flange face, Small
size T/S, Pipes of smaller diameter,
 SMAW – Shielded Metal Arc Welding. Applicable to small
components and repairs of clad.

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 6. Electro Slag Strip Cladding (ESSC)

 ESW is an arc less method using Joules Effect to melt the

strip/flux/parent material.
 The heating is a result of current flowing through the strip electrode
and a comparatively shallow layer of liquid electro conductive slag.
 The penetration is lower for ESW than for SAW since the molten slag
pool is used to melt the strip and some of the parent material rather
than as an arc between the strip electrode and the parent material.
 Electro slag strip surfacing reduces dilution by up to 50% compared
with submerged arc strip surfacing for the same heat input with a
significantly higher deposition rate.
 In ESSC a strip electrode is continuously fed into a shallow layer of
electrically conductive flux.
 The heat required to melt the strip, the slag-forming flux and the
surface layer of the base metal is generated by resistance heating
due to the welding current flowing through the molten conductive
slag.

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 Electro slag strip cladding is a development of submerged arc strip
cladding, which has quickly established itself as a reliable high
deposition rate process.
 The heating is a result of current flowing through the strip electrode
and a comparatively shallow layer of liquid electro conductive slag.
 The penetration is lower for ESW than for SAW since the molten slag
pool is used to melt the strip and some of the parent material rather
than as an arc between the strip electrode and the parent material.
 As a rule of thumb, electro slag strip surfacing reduces dilution by up
to 50% compared with submerged arc strip surfacing for the same
heat input with a significantly higher deposition rate.
 However, as a result of the lower dilution levels for ESW, new strip
compositions have been developed for ESW, in particular for
applications where the aim is to obtain a certain weld metal
chemistry.

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 It is used for welding heavy wall thickness vessels of different kinds
and many more applications.
 Technological developments have driven temperatures and
pressures used in the petroleum, chemical, pulp, and paper, and
environmental protection industries, and increased the likelihood of
serve corrosion and wear in the process pressure vessels.
 The industries must improve the corrosion and wear performance of
these major components.
 Economic factors as rule will not permit fabricating components
from solid high alloyed material.
 As a consequence, it is necessary to surface non-alloyed or low alloy
base material with high alloy cladding.

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 Process Principle: -

 ESSC is an arc less welding process. The process start within arc
between continuously fed filler strip and base metal, which results in
initial meeting of flux.
 The slag formed, becomes electro-conductive in molten state due to
presence of special ingredients, support passage of current at lower
voltages and the arc gets extinguished.

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 The heat, which is requiring melting the strip and continuing the
process is generated by Joule Effect as a result of current flowing
through the electro-conductive slag.
 Molten droplets formed at the strip end, travel through the molten
superheated slag due to higher density and reach the base metal.
 This is the single most important feature of the process, since it
results in dilution less than 15%. The dilution can be further reduced
to 5-10% by controlling various interacting parameters.
 In electro slag strip cladding the heat required to melt the base metal
and the strip electrode is not generated by an electric arc; the Joule
effect is utilized instead.
 The current flows through the strip and into a layer of electrically
conductive slag; the resistance of this material generates the heat
and keeps the welding process going (slag temperature
approximately 2300°C)
 In ESSC process, the arc must be extinguished once it has been ignited
and the current flow through the slag. As a consequence, the
following must apply:
RA =>infinity; IA = 0
Where RA is the resistance in the arc and IA is the current in the arc.
 If these conditions are to be satisfactory, the electrical resistance for
the slag must be less than that for the arc.
 This presupposes that the electrical conductivity of the liquid slag
created during the ignition process will rise with the rising
temperature (or, the specific resistance is dependent on the
temperature and is going down with rising temperature).

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 If the process is to be stable, the thickness of the layer and the surface
of the slag pool must be kept constant.
 This is affected by continuously melting flux, which is fed at one side
only.
 To retard the interface resistance; it is important that the strip
electrode has a sufficient depth in the slag pool.
 In ESSC process the resistance heating of the slag melts the fillet
metal and the base material.
 Electro slag surfacing is thus classified as a resistance welding
technique.

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 Factors affecting on process: -

1) Ferrite
2) Dilution
3) Shrinkage
4) Distortion
5) Preheating requirement
6) Welding parameters
7) Deposition rate
8) Fluxes
9) Chemical composition

 some important factor shows below: -

Dilution:
“Basically dilution is weight of base metal melted divided
by the total weight of weld metal.”

 An important factor to consider in ESSC is dilution.

 In any overlay process, the weld metal deposited gets mixed with the
base metal in the molten state, thereby giving a slightly leaner
composition.
 Thus, the properties of this part of the bead will be slightly
compromised due to the change in the chemical composition.
 The amount of dilution can be calculated by using the formula: -
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 𝐵
%𝐷𝑖𝑙𝑢𝑡𝑖𝑜𝑛 = ∗ 100
𝐴+𝐵

 The width ‘a’ of the bead will retain the required properties of the
clad material, as it experiences no change in chemical composition.
 The amount of dilution is dependent on the overlay-process and
process variables such as current, travel speed and thickness of
material that will be joined and also the welding procedure.
 Excessive base metal dilution, as with other metals, can induce
cracking along the fusion line and must be controlled by using proper
welding consumable and welding technique.
 Dilution is also an important consideration for determining the
number of weld-layers to be provided for corrosion resistance.

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 Some multi-pass welded beads may have a little variation in
composition in each weld layer due to the process control and
technique employed.
 The filler metal’s first layer should be able to tolerate at least up to
30% dilution and still should be able to yield an acceptable deposit.
 Welding parameters must be selected in such a way that fusion with
'minimum dilution is obtained.

Effect of current: -
 Current increases
 Penetration, Bead width & bead thickness increase
 Dilution decreases

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 Effect of travel speed – Speed increases

 Penetration & dilution increases

 Bead width & bead thickness decreases

Fig. 7.7 Effect of Travel Speed changes during welding

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 Effect of Voltage – Voltage increases

 Penetration, bead width, bead thickness

 Dilution also increases

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 Effect of stick-out – Stick-out increases

 Bead width & bead thickness increases

 Penetration & dilution decreases
 (Shown in Figure 7.9)

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 Deposition rate of ESSC

 The electro slag strip cladding method was developed in the early
seventies to increase productivity by increasing the deposition rate
and decreasing the dilution compared with the SAW process.
 Due to the properties of ESW often only one layer is needed to fulfill
the cladding requirements and further the consumption of
consumables is significantly reduced.
 ESW can be advantageously used for the productive cladding of a
second layer, when the two-layer technology is demanded. The first
layer, usually a buffer layer, cans be deposited with either SAW or
ESW.

Typical features:

 Flux is fed only from the front side of the strip.

 Visible weld pool at the rear side of the strip.
 Radiation only in the visible and infrared spectrum, no ultra violates
radiation because of the absence of any arc.
 The weld pool size being big is subjected to metal flow as a result of
electromagnetic forces exerted by passing current.

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 External magnetic fields are required to be superimposed to control
the bead shape.
 An additional feature, known as magnetic steering device, is use to
carry out this function. Higher Current - Bigger weld pool  Requires
Magnetic Steering Device (MSD)
 Very High Deposition Rate
 Individual Layer thickness: 4~6mm
 Dilution: 10% (SASC - 20~30%) - Chemistry achieved even in Single
layer
 Electro slag strip cladding is the modified version of submerged arc
strip cladding process.
 The heat generation in the case of ESSC is due to the current flowing
through the electro conductive slag.
 Automatic removal of the slag crust.
 Very regular, finely ripped bead, without any slag adherence.

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Strip Size in Welding Welding Bead width Deposition rate
mm(0.5thk) current Voltage mm Kgs/ Arc Hr.

30 550 - 650 22 - 24 32 – 36 10

60 1250 - 1300 23 – 25 63 – 66 22

90 1700 - 1800 24 – 25 93 – 97 33

120 2200 - 2400 24 - 25 124 - 128 42

• Welding Speed = 140 to 180 mm/min

• Stick out = 28 to 32 mm
• No arcing except in staring
• Flux is fed only in front
• Strip is cut 45° taper while staring

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Operating Variables & Parameters: -
Variables:
1. Welding current polarity
2. Welding Current intensity
3. Welding voltage
4. Welding travel speed
5. Stick out of the Strip
6. Flux burden
7. Bead overlap
8. Altitude of the electrode
9. Welding position
10. Base metal surface condition

Welding travel speed:

 Depends on desired thickness of surfacing layer

 Higher welding speed as compared to SASC – as a result of greater
current density & greater melting rate
 For 4 mm thick layer, welding speed will be 160-200 mm/min
 Speed > 200 mm strip electrode tends to run away from slag pool
(Current & melting rate constant)
Stick out of the Strip:

 Length of free strip electrode measured from the strip end to contact
shoe

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 Varies between 25-40 mm
 Stick out increases –Bead Width & Bead Thickness increases
 Stick out increase – Preheat of strip increases -Deposition rate
increases – Dilution decreases
Stick out Dilution
30 mm 17.7%
35 mm 15.5%
40 mm 13.5%

Bead overlap:
 Distance between edge of the strip electrode & the edge of the
previous bead
 Overlap ranges between: 5–10 mm (2-5 mm preferred)
 Thicker the bead – Smaller is the overlap needed
 Steeper the bead – Smaller is the overlap needed

Base metal surface condition:

 The surface to be overlaid should be free from any sort of oxides, rust,
oil, adhesives etc.
 Otherwise, irregular electrical contact and improper slag metal
interaction occur.

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  Best surface preparation is grinding. If the surface area is too large,
shot blasting can be done. Wire brushing is enough for light scale on
base plate.

SMAW FCAW Thin SASC ESSC ESSC ESSC

wire
SAW
Electrode/Strip 4.0 1.2 1.6 60*0.5 60*0.5 90*0.5 120*0.5
Size (mm)
Current 175 230 350 750 1200 1800 2300
(Ampere)
Dilution (%) 25-30 25-30 30-35 20-30 7-13 7-13 7-13

Depth of 1.5-2 1.5-2.0 2.0-2.5 1.5-2.5 0.8-1 0.8-1 0.8-1

Penetration
(MM)
WM 0.5 1.0-1.5 4.5-5.0 13-14 22 33 42
Deposition
Rate (KG/Arc-
Hrs.)

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 Defects:

 After ESSC we should need to examine that overlay, to ensure that

there are no chances to base metal corrosion or contact with liquids
which are place in vessel.

 So, first of all we have done Visual Testing of clad overlay.

 Than after attending that point, we have test that with another NDE
process which is Liquid Penetrant Examination.

 There are some defects are described, which are commonly occurred
in ESSC.

Defects found in the ESSC welding:

1. Slag inclusion.

2. Lacks of inter bead fusion.

3. Improper bead shape.

4. Crater crack.

5. Centerline cracks.

6. Porosity

7. Under cut
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 Slag inclusion:

 Slag inclusion is a very common defect in the any welding process.

Reason:

 Improper bead shape.

 More bead overlapping.
 Improper cleaning of the slag.
 Poor slag detachability of the flux.

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 Solution:

 Adjust the parameter to get bead proper slope at toe.

 Maintain correct bead overlap before start of the overlay. It should be
in the 2-5 mm. Not more than it.
 Proper cleaning of the bead with power wire brushing and blades.

Lack of inter bead fusion:

 When we are doing overlapping of the bead in the any welding

process, at that time if we are not take care of proper overlap so
the over bead may not be fuse with the under bead 100%, and
there the chances of the lack of fusion.

Reasons:

 Improper bead shape

 Thickness of the layer is very high.
 Use of less current.

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 Solution:

 Take care at the time of the welding that the bead must be sat on
the other bead.
 Use correct welding parameter and especially travel speed.
 Check the ampere meter and other electronics device before
starting the welding and change it if required.

Improper bead shape:

Reasons:

 Incorrect / wrong settings of Magnetic Stripping Device.

 Generating jerks in the welding head/ tank rotator.
 Current fluctuation.
 Incorrect bead overlap.
 Flux height may be very high.

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 Solution:

 Connect shoes face should be polished & tight properly.

 Check earthling lug and power source.
 Set proper current & polarity.
 Set correct bead overlap.

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 Crater crack:

Reasons:

 Improper cleaning of surface.

 Less flux height.

Solutions:

 Surface must be cleaned properly before starting the welding.

 Flux height may not be higher than stick out +7mm

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 Centerline crack:

Reasons:

 Use of improper strip.

 Use of improper flux.

 Improper bead slope in the overlap area.

 Lesser flux height.

 Improper setting of molten pool.

 Improper cleaning of the surface.

 Use of very high current.

 Inter pass temperature may not be maintained.

Solutions:

 Check the strip and flux before use in the welding.

 Overlapping must not be more then 2-5mm.

 Flux height should be stuck out +7mm.

 Set the parameter before starting the welding.

 Surface must be clean properly.

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 Porosity:

Reasons:

 Improper cleaning of the surface.

 Improper shielding of the molten pool.

 Use of cold/unbaked flux.

 Contamination of foreign particles with the strips and flux.

Solutions:

 Check the flux baking period before use.

 Clean properly before use of the recycled flux.

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  Clean the surface before start the welding.

 Take care of the proper shielding of the molten pool.

Under cut:

Reasons:

 Less current.
 High travel speed.
 Wrong setting of the polarity in the magnetic stripping device.
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 Solutions:

 Use proper parameter.

 Check the all device at the time of the trial.

Valley:

Reasons:

 Drift in shell rotation

 Slight error in magnet steering device setting.
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 Solution:

 Nullify the drift in shell rotation.

 Correct the magnet steering device setting.

Problems found during welding and it’s troubleshooting:

 Strip fuse uneven in some portion

 Strip is stick with base metal
 Water leakage from cooling shoe.

Strip fuse uneven in some portion:

 In this case ESSC strip fuse uneven while welding on D’end.

 As shown in Figure.
 After some analysis we have got that the strip is coming uneven,
so there is chance that fusion of strip is uneven.
 Immediately call the maintenance department and repair the
motor for further welding.
 Grind that portion and after test that portion with LPE, re weld
that portion after maintenance done.

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 Water leakage from cooling shoe:

 In this case water is leakage from cooling shoe while welding thus
slag is not properly removed after welding.
 As shown in figure
 After some analysis we have done that, the pipe of cooling shoe
is loose so water is fall on weld pool while welding
 There is chance to slag inclusion.
 Then, Grind that portion with wire wheeling properly.

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CLADDING Page 39
 Acceptance Criteria for overlay weld:

Sr. Type of Acceptance Sketch for Reference

N. Observation criteria
1 Conformity to Drawing, WPS ---
drawing
requirements
including overlay
thickness
2 Excessive Minimum weld ---
grinding overlay
thickness is
available
3 Adequacy of Allowances ---
machining considering
allowance finished
dimensions as
per drawing
4 Crack Not acceptable

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5 Variation in ESSC – 5 max
height Other
Of overlay Processes –
between 3.5mm max
- Adjacent Minimum weld
passes overlay
- Adjacent thickness is
beads within available. Start
the pass & end point to
be smooth
merged.
6 Inter bead Valley 1.0 mm max
Minimum weld
overlay
thickness is
available
7 Mechanical Not acceptable ---
damage
8 Porosity Not acceptable

9 Slag inclusion Not acceptable

10 Spatter Not acceptable

11 Sharp edges Sharp edges ---

felt with

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 fingertip is not
acceptable
12 Under cut <= 0.5mm
max.
>0.5mm shall
be smooth
merged
Minimum weld
overlay
thickness is
available
13 High Peak Point High peak
point is
allowed up to
1mm, More
than this value
shall be
ground
14 Offset between 1) No sharp
adjacent beads corner is
acceptable,
2) 1mm Max,
Offset shall be
allowed.
15 Crater cracks Not acceptable

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 Advantages, Disadvantages & Application

Advantages

 The simplicity in use is very great, in principle it needs only the

same type of equipment as the submerged arc strip cladding
technique
 The electro slag technique offers much higher deposition rates
compared to the sub arc technique.
 The dilution with the base metal remains very low; typically,
dilution rates are between 7 and 10 %.
 A very stable and regular welding process with an extremely low
defects risk, such as slag inclusions, lack of penetration…
 Better surface finish.
 Lower flux consumption rate.
 Productivity is very high.
 Lower penetration level (about 0.5mm)
 Better bead characteristics.
 Trouble free operation.

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 Disadvantages: -

 Flux required is more than the SAW process.

 Lower flux consumption rate.
 Difficulty to see the weld.
 Very low working speed.

Application: -

 The process is usually confined to relatively large and thick

components which need to be manipulated to enable welding to
be carried out in the flat position.
 The technique finds its widest application in the oil, gas and
fertilizer related industries and in the nuclear power generation
field.
 Generally used for surfacing the internal surfaces of pressure
vessels and large diameter pipe and in the reclamation of steel
mill rolls.
 Heavy plates, forgings and castings can be butt welded.
 Subsequent alloys can be welded:
 Low carbon and medium carbon steels.
 High strength structural steels

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  High strength alloy steels such as stainless steel and nickel alloys.
 Longitudinal stiffeners of the upper deck of ships.
 Longitudinal welds in cylindrical pressure vessels.
 Shells for blast furnaces and basic oxygen furnaces.
 Flange face, weld cladding inside.
 Vessels for off shore industries.
 Tube for process furnace.
 Vessels for petrochemicals.
 Bottom of gas cooler.
 Fittings for petrochemicals.
 Column for cellulose industries.
 Chemical processing reactor, etc.

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 7. Submerge arc strip cladding (SASC)

 Uses the arc that runs back and forth at high speed along the
strip.
 Arc causes more penetration in base metal that causes more
 Amount of dilution of about 20%.
 Deposition rate: 12-14 kg/h for 60x0.5mm strip.
 Current range restricted to limit dilution.

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 Difference between SASC & ESSC

SASC ESSC

Flux - Agglomerated Flux – Electro slag

Continuous Arc between strip & No Arc except in the starting

BM

Flux fed on both side of strip Flux fed only from front side

Comparatively low Amp High Amp

Comparatively low deposition rate High deposition rate

High consumption of flux Low consumption of flux

Comparatively high penetration & Low Penetration & low

dilution dilution

Minimum two layers required Single layer can also meet

requirement

Arc fully covered with flux Back side fusion visible

Low hot cracking sensitivity Very low hot cracking

sensitivity

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 Advantages: -

 Higher deposition rate.

 Best suitable for similar parts.

Disadvantages: -

 Positional incapability (2G and Magnet).

 Consumable cost is high.
 More rework.
 Dilution is more comparing to ESSC.

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 8. Flux Cored Arc Welding: -

 This process is variant of GMAW process. The only difference

between them is the electrode which is flux cored as name
suggests.

 The flux enclosed in tubular wire on burning produces gas for

shielding the molten metal and also provides deoxidizers, ionizers
purifying agents and if required than alloying elements.
 Flux on melting results in formation of glasslike slag which provide
thin protective layer on weld bead.

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 Advantages: -

 Can be automated.
 Composition of deposit can be easily controlled.
 Can obtain required weld bead geometry

Disadvantages: -

 Flux cored wire is very costly.

 Special arrangement is required to remove fumes.
 Slag inclusion can be there.
 Very much rework.

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 9. GAS TUNGSTEN ARC WELDING (GTAW): -

 Gas tungsten arc welding (GTAW) is an electric arc welding

process that produces an arc between a non-consumable
electrode and the work to be welded.
 The weld is shielded from the atmosphere by a shielding gas that
forms an envelope around the weld area.
 It is used to weld thin sections of stainless steel and non-ferrous
metals such as aluminium , magnesium, and copper alloys

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 DEFECT OF GTAW: -
1. Cracks 2. Lack of Fusion
3. Porosity 4. Undercut
5. Lack of Penetration 6. Excess Penetration
7. Overlap 8. Suck Back
9. Under Flush 10. Burn Through
11. Tungsten Inclusion 11. Stray Arcing

ADVANTAGES: -

 Can be automated.
 “Zero defect”.
 Hot wire GTAW can have higher productivity with quality.
 Cost effective.

DISADVANTAGES: -

 Productivity is low if hot wire is not used.

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 10. SUBMERGE ARC WELDING

 This welding process also called as manual metal arc welding.

 It uses metallic consumable electrode of a proper composition for
generating arc between itself and the parent work piece.
 The molten electrode metal fills the weld gap and joins the work
pieces.

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 COMMON DEFECT IN SMAW: -
1. Crack 2. Lack of Fusion
3. Slag 4. Porosity
5. Pinhole 6. Piping
7. Undercut 8. Overlap
9. Lack of Penetration 10. Excess Penetration
11. Spatters 12. Suck Back
13. Under Flush 14. Burn Through
15. Uneven Bead 16. Stray Arcing

ADVANTAGES: -

 Excellent positional capability.

 Lower initial cost.
 Weld pool can be easily manipulated.

DISADVANTAGES: -

 Manual process.
 Lower deposition rate
 Costly consumable.

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 11. DEPOSITION RATE OF OVERLAY PROCESS:

PROCESS DEPOSITION RATE

(Kg/Arc.hr)

ESSC/SASC 22

GMAW 3-3.5

FCAW 3-3.5

GTAW 0.5-1

HOT WIRE GTAW 1-2

SMAW 1-1.5

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 12. COST ANNALISIS FOR DIFFERENT PROCESS

PROCESS CONSUMABLE
COST(Rest./Kg)

ESSC\SASC 180 + 140 (FLUX)

GMAW 150

FCAW 350

GTAW 150

HOT WIRE GTAW 150

SMAW 220

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