Submerged arc welding (SAW) is a process where the arc and molten pool are concealed under a layer of granular flux. An electric current is passed between the continuously fed electrode wire and workpiece, heating them to fuse the metals. Key advantages include high quality welds, high deposition rates, and the ability to weld thick plates. Applications include boilers, pressure vessels, ships, and structural fabrication.

1. Gujarat technological university
Birla vishwakarma mahavidhyalaya
Guided by:
PROF. R.S.BAROT
RATHOD ANKIT (140070125026)
SHAH RUSHI (140070125027)
SHAH VRAJ (140070125028)
SHIYAL VIKRAM (140070125029)
SUBJECT: METAL JOINING PROCESSES
(2162107)
Prepared by :
TOPIC: SUBMERGED ARC WELDING (SAW)

2. Submerged Arc Welding
 Submerged arc welding (SAW) is a method in
which the heat required to fuse the metal is
generated by an arc formed by an electric
current passing between the electrode and the
work piece.
 There is no visible arc and no sparks, spatter or
fume. Arc and molten pool remains completely
hidden.
 This arc submerged under the loose granular
flux.

3.  The submerged arc welding flux feeds through the
hopper tube and continuously distributes itself over
the seam a short distance ahead of the welding zone.
 The wire feed mechanism begins to feed the
welding into the joint at a controlled rate.
 An electric arc is established as the current flows
between the electrode and the work.

7. Arc initiation
 After arranging the polarity ,arc struck
either by touching electrode of w/p or
by placing steel ball wool
 No withdrawn facilities available for
arc initiation , ball of thin wire is placed
at working of electrode
 So technique adopted for arc initiation
is called ball wool wire method.

8.  For arc initiation, electrode touches the
ball of thin wire of steel which has very
small gauge.
 The ball is kept on contact with w/p, the
wire ball wool virtually fuse and
vaporised by providing electrical supply.
 Initially flux works as insulated but it
melt as due to arc heat & become
conductivity & began to start arc.
 Further causing melting and ionization
of electrode wire.

9. Why touch & draw is not used
?
 In SAW process the wire is fed
automatically by motor only in forward
direction only.
 For touch & draw method anyone
have to add more facilities on m/c for
draw , moment will have to be control
by motor which makes automation
difficult.

11. Advantages
 High quality
 Little risk of undercut and porosity
 No spatter
 High current upto 4000A is used
 High deposition rate upto 20kg/h because arc is
completely confine by granular flux.
 High thermal efficiency
 weld upto 75mm thick plates
 High welding speeds are possible upto 5m/s
 No edge preparation required
 Neat appearance

12. Limitations
Precise joint preparation required
No observation of arc and process during
welding is possible
Limited to flat position .
It can not be used for plates less than 5mm
thickness
Flux is subjected to contamination and
absorption of moisture.
Flux consumption is high
Irregular wire feed.

13. Applications
 Fabrication of Boiler Pressure Vessel.
 Railroad tank cars.
 Structural shapes and cylinders.
 Circular welds and Longitudinal pipe welding.
 Beam Production.
 Ship Building.
 Circumferential welding in wind tower
fabrication.