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1、Introduction of SAW welding,Principle of SAW method,The flux should completely cover the arc. The stick out is approximately 30 mm, but can in some cases be considerably more.,Stick-out,Submerged Arc Welding (SAW),High Productivity- High amperage is possible- Deslagging is easy High Quality- Deep pe
2、netration- Excellent mechanical properties Good Environment- Very little fume- Easy operation,Range of application,Plate thickness and edge preparationUse I - joints for plate thickness about 2 - 12 mmUse Y - joints or double Y - joints above 12 mmThe joint must be accurately cut.Gaps, if any, must
3、not exceed 1 mm.The joint should have a proper bottom section, consisting either of parent material, a backing bar or hand welded root bead to withstand the deep penetration which is typical for Submerged Arc Welding,Examples of SAW machines,Important when welding SAW,The plates have to be straight.
4、 The plates have to be clean, preferably ground or shot blasted. The positioning of the wire is of greatest importance. The flux should cover the arc completely (not necessarily cover the wire completely) The flux should be dry.,Productivity comparison,There are several ways to increase productivity
5、 further, relative to single wire only:Twin-arc: Welding with two wires and one power source.Tandem: Welding with two wires and two power sources.Grain: Welding with the addition of metal powder.Cold wire: Welding with the addition ofcold wire.,Twin - arc welding,DC powersource,+,-,Twin - arc weldin
6、g,Parallel power - 50% greater deposition rate,Tandem,Butts & Fillets,Side by side,Skewed,Cladding,Avoids burn through,A6 Twin arc,A6S W/Twin Arc Kit,Tandem arc Welding,AC powersource,DC powersource,+,-,Direction of welding, 30 mm,Tandem arc Welding,Single pool - Highest deposition rate,Twin pool -
7、Travel speed limited by undercut Very resistant to porosity and cracks,A6 Tandem Subarc,Iron Powder feed unit,Highly increased welding speed and deposition rate Reduction of dilution from parent metal giving higher impact strength Easily fitted to standard A2/A6 welding equipment,Iron Powder Feed Un
8、it,Synergic cold wire kit (SCW),Productivity comparisonISO joint with OK 10.71 flux and OK 12.22 wire (3.0 mm hot and 2.0 mm cold) 500A, 32-33V and 33m/h.3 mm DC+ 20 beads 3+2 mm DC+ 13 beads 3 mm AC 18 beads 3+2 mm AC 12 beads,Productivity comparison,Welding method Speed in cm/min for a9 mm butt jo
9、intManual Metal Arc (MMA) 10 -11Semi-Automatic FCW 25Single wire SAW 45Twin wire SAW 53,Deposition rate with SAW,The deposition rate is shown as a function of wire diameter and amperage.,200 400 600 800 1000 Amp,Kg/h161412108642,a,b,e,f,g,c,d,Wire diametera = 1,6 mm b = 2,0 mm c = 2,4 mm d = 3,2 mm
10、e = 4,0 mm f = 5,0 mm g = 6,0 mm,Deposition rate with SAW,Recommended current range and deposition rates (Kg/h) for different wire diameters,Flux consumption,kg/m,Welding speed in m/h,0,4,0,3,0,0,1,0,2,40,80,60,100,160,140,120,Influence of Amperage and Voltage,Higher amperage gives deeper penetratio
11、nHigher voltage gives wider penetration. The arc length gets extended.,Influence of electrical stick-out,Longer stick-out gives higher deposition rate, but also more shallow penetration.Above: Penetration at different stick-out Right: Deposition rate at different stick-outs.,A: 25 mm B: 57 mm C: 83
12、mm,Influence of polarity and wire diameter,Deepest penetration with positive electrode. Normally, the welding machine is equipped with DC positive electrode.At constant amperage, the penetration gets deeper with smaller wire diameter, due to the higher current density.,Influence of wire angle,The wi
13、re angle influences both penetration, the weld convexity, and the tendency to undercutting.Backhand gives high penetration, narrow and high weld convexity, and relatively high risk for undercutting.Vertical welding gives normal values. Forehand gives low penetration, wide and low weld convexity, and
14、 relatively slight risk for undercutting.,Backhand Vertical Forehand,Examples of incorrect weld joints,Welding with too high current and / or too slow speed, results in an incorrect cross - section. There is a big risk for cracking.Too high voltage can cause an incomplete penetration.,Root defect,Market segmentation Automatics,We make it possible!,
