Submerged arc welding uses a bare wire electrode that is continuously fed and submerged under a blanket of flux powder. This powder protects the weld area from contamination and aids in welding metals. The arc is created below the surface between the electrode and workpiece. It allows for high deposition rates due to high current. Electro slag welding is used to weld thick sections in a single pass using multiple vertically fed electrodes. Molten slag pools on top of the weld area and generates heat through electrical resistance to complete the weld. Both methods provide smooth, deep welds suitable for industrial applications.

1. 1113 April 2020 Dr.Abhishek Sharma
By
Dr.Abhishek Sharma
Metal Joining
(Submerged Arc, Electro Slag, Arc Atom Welding)
KME-403
Unit - IV
GL BAJAJ INSTITUTE OF TECHONOLOGY & MANAGEMENT

2. 2
Submerged Arc Welding:
Automatic form of SMAW and can be used in straight line joining of metals.
• Bare metallic, copper plated electrode in form of long coiled wire is used .
• Copper used to ensure low resistance electrical contact between wire & contact shoe. Arc is
created between electrode and workpiece.
• The arc, the end of the electrode and molten weld pool are submerged in a finely divided
granulated powdered flux containing appropriate deoxidizers, cleansers, and fluxing elements.
• Flux powder is fed from hopper.
•Tube from hopper spreads powder continuously in front of electrode in the line of weld.
13 April 2020 Dr.Abhishek Sharma

3. 3
• Un melted flux is removed by suction system and can be reused.
• Uses high current ranging between (300 to 400) Amp.
Advantages:
• Use of high current gives high deposition rates.
• Deep weld penetration.
• Process thermally efficient.
• Weld beads are extremely smooth.
• Used in rebuilding and hard surfacing rolls.
Disadvantages:
• Weld cannot be seen, thus difficult.
• Limited to flat positions only.
• Overhead welding is impractical.
13 April 2020 Dr.Abhishek Sharma

4. 4
• These molecules also form the blanket avoiding oxygen.
• Normally AC is used, since better regulation is possible and reversing polarity equalizes
electrode deterioration.
• It gives high heat concentration.
• Can be used for alloy welding , H2 acts as shield thus no shielding gas required.
13 April 2020 Dr.Abhishek Sharma

5. 5
Electro Slag Welding:
• Used to weld seams of thick section in single pass.
• Plates to be welded are placed in a vertical position, so that molten metal is delivered
progressively to vertical gap.
• 2-3 electrodes are used which are fed vertically.
• Powdered granular flux is poured from hopper.
13 April 2020 Dr.Abhishek Sharma

6. 613 April 2020 Dr.Abhishek Sharma
Advantages:
•Automatic process with uniform heating
Disadvantages:
•Used for thick plates only
• In starting arc is created b/w electrode and bottom plate and continued until a sufficient thick
layer of molten slag is formed.
• Arc only initiates melting, thereafter heat is generated by electric resistance offered by the
electrically conducting slag.
• A mechanism for raising the equipment as weld is completed is also used.
• AC power source delivering 1000A is used .
• Shielding gas like CO2 is also used.