Submerged Arc Welding (SAW)

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  Submerged Arc Welding

Submerged Arc Welding (SAW) is a welding process that utilizes an arc between a continuous wire electrode and the workpiece. The arc is submerged beneath a layer of granular flux, which protects the weld from atmospheric contamination. SAW is commonly used for welding thick sections of steel and is known for its high deposition rates and deep penetration. Here's an overview of the SAW process:

Materials and Equipment:

  1. Welding Machine: SAW requires a specialized welding machine designed for the process. It typically includes a power source, wire feed mechanism, and control panel.
  2. Wire Electrode: SAW uses a continuous wire electrode that is typically solid or cored, depending on the application and material.
  3. Flux: Granular flux is used to create a protective layer over the weld. The specific type of flux depends on the material being welded.
  4. Welding Head: The welding head holds the wire electrode and flux delivery system. It is moved along the joint to create the weld.
  5. Power Source: The power source provides the electrical current needed to generate the welding arc.


The Submerged Arc Welding Process:

  • Joint Preparation:
  • Clean the base metal surfaces and prepare the joint to the specified dimensions.
  • Ensure that the workpieces are properly aligned and secured.

  • Setup:

  • Load the wire electrode and the appropriate granular flux into the welding head.
  • Adjust the welding machine's parameters, such as voltage, current, and travel speed, based on the material and joint specifications.

  • Flux Application:

  • The flux is continuously delivered onto the joint by a hopper or feeder attached to the welding head.
  • The granular flux forms a protective layer, which covers the arc and weld pool, preventing atmospheric contamination.

  • Welding Process:

  • The welding head is positioned at the beginning of the joint.
  • The arc is initiated, and the wire electrode is continuously fed into the joint.
  • The heat from the arc melts both the wire electrode and the base metal, creating the weld pool.
  • As the welding head progresses along the joint, it leaves a solidified weld behind.

  • Cooling and Post-Weld Cleaning:

  • Allow the welded joint to cool naturally, or use cooling blankets to speed up the process.
  • After the weld has cooled, remove any remaining flux and inspect the weld for quality and integrity.

  • Quality Control and Inspection:

  • Inspect the weld for any defects, such as cracks, inclusions, or incomplete fusion.
  • Perform any required testing or quality checks to ensure the weld meets the specified standards.
Clean Up:
  • Turn off the welding machine and any associated equipment.
  • Dispose of used flux and clean the work area.

    Submerged Arc Welding is commonly used in applications where high-quality, high-speed welding is required, especially for thick sections of steel. It is known for its efficiency and ability to produce sound, uniform welds. Proper safety precautions, including personal protective equipment, are crucial when performing SAW, as it involves high heat and potential exposure to fumes and radiation.

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