ESTABLISHING RELATIONSHIP BETWEEN WELDING CURRENT AND WELD METAL DEPOSITION RATE FOR SOLID WIRE IN SUBMERGED ARC WELDING PROCESS

2020 ◽  
Vol 15 (2) ◽  
Author(s):  
Bashkar R ◽  
Balasubramanian V ◽  
Mani C
Keyword(s):  
Weld Metal ◽  
Deposition Rate ◽  
Arc Welding ◽  
Welding Process ◽  
Welding Current ◽  
Submerged Arc Welding ◽  
Metal Deposition ◽  
Wire Diameter ◽  
Filler Wire ◽  
Submerged Arc

Submerged Arc Welding (SAW) process is used to weld large, heavy metal deposition jobs with critical requirements, and this metal joining process alone is used to weld approximately 10% of the deposited weld metal worldwide. Any augmentation in productivity of SAW process, will immensely benefit the welding industry, as this process is widely used on variety of common metals and alloys. This paper focusses on establishing relationship between welding current and productivity (in terms of weld metal deposition rate as an index), for a given filler wire diameter. Productivity rates of most common solid filler wire sizes were studied, at different preset current values, covering full current range through bead-on-plate experiments. At each preset current value, the bead was first optimized for acceptable visual quality, by varying arc travel speed and voltage, then wire feed rate (of acceptable beads) was noted. The current density, heat input and corresponding weld metal deposition rate were calculated for establishing relationships. The established relationships can be effectively used, to estimate productivity from the preset current values, for a given solid wire diameter.

TMF Influence on Weld Structure at the Welding of 12X18H9T

2018 ◽  
Vol 927 ◽  
pp. 1-5 ◽  
Author(s):  
Alexander D. Razmyshlyaev ◽  
Marina V. Ahieieva ◽  
Elena V. Lavrova
Keyword(s):  
Magnetic Field ◽  
Weld Metal ◽  
Arc Welding ◽  
Welding Process ◽  
Metal Structure ◽  
Transverse Magnetic ◽  
Submerged Arc Welding ◽  
Structural Components ◽  
Weld Structure ◽  
Submerged Arc

The transverse magnetic field (TMF) use allows to obtain follow effects: increasing the electrode melting coefficient, reducing the base metal penetration depth and grinding the weld metal structural components. The paper analyzed the existing literature data about the TMF influence on the refinement of the weld metal structure. It is experimentally shown that the alternating TMF influence of 6 Hz frequency reduces the grain size of weld metal is almost twice in comparison with the welding process without the TMF influence at submerged arc welding of plates of austenitic steel type 12X18H9T (X10CrNiTi18-9). The average grains size is 7-6 index, when welding without the TMF influence and the average grains size of the weld metal corresponds to 8 index, with separate inclusions of grains with 7 index when welding with the TMF influence. This is should increase the yield strength value of the weld metal in accordance with the data of Hall – Petch.

Some Feasibility Studies for Recycling of Steel Slag as a Useful Flux for Submerged Arc Welding

2020 ◽  
Vol 19 (02) ◽  
pp. 277-289
Author(s):  
Sumit Saini ◽  
Kulwant Singh
Keyword(s):  
Weld Metal ◽  
Arc Welding ◽  
Steel Slag ◽  
Welding Process ◽  
Feasibility Studies ◽  
Submerged Arc Welding ◽  
Bead Geometry ◽  
Weld Bead Geometry ◽  
Arc Welding Process ◽  
Submerged Arc

Protection of environment from industrialization and urbanization waste is the prime duty of engineers and researchers. Elimination of industrial waste completely is not possible because it is generally a byproduct of the process. It can be minimized by recycling or reusing. In this research, waste slag generated by steel plant is recycled as a useful flux for submerged arc welding. It is found that recycled slag is capable of producing acceptable weld bead geometry. The penetration achieved using recycled slag is 7.897[Formula: see text]mm, which is more than the penetration obtained using fresh flux, i.e. 6.027[Formula: see text]mm. The reinforcement produced by recycled slag is 2.632[Formula: see text]mm, which is close to the reinforcement obtained using fresh flux. It is further observed that chemistry of weld metal deposited using recycled slag is also at par with that of weld metal produced using fresh original flux. The amount of carbon present in weld metal produced by recycled slag is 0.15%, which is comparable to the percentage of carbon present in weld metal produced using fresh flux. The microstructure and microhardness obtained using recycled slag are also comparable with the microstructure and microhardness obtained using fresh flux. This research established the feasibility of recycling slag as a flux required for submerged arc welding process.

Development of Welding Procedures for X90-Grade Seamless Pipes for Riser Applications

2012 ◽  
Author(s):  
Hiroyuki Nagayama ◽  
Masahiko Hamada ◽  
Mark F. Mruczek ◽  
Mark Vickers ◽  
Nobuyuki Hisamune ◽  
...  
Keyword(s):  
Weld Metal ◽  
Arc Welding ◽  
Mechanical Test ◽  
Welding Process ◽  
High Strength ◽  
Submerged Arc Welding ◽  
Welding Parameters ◽  
Flux Cored Arc Welding ◽  
Welding Procedure ◽  
Submerged Arc

Ultra-high strength seamless pipes of X90 and X100 grades have been developed for deepwater or ultra-deepwater applications. Girth welding procedure specifications (WPSs) should be developed for the ultra-high strength pipes. However, there is little information for double jointing welding procedure by using submerged arc welding process for high strength line pipes. This paper describes mechanical test results of submerged arc welding (SAW) and gas shielded flux cored arc welding (GSFCAW) trials with various welding consumables procured from commercial markets. Welds were then made with typical welding parameters for riser productions using high strength X90 seamless pipes. The submerged arc weld metal strength could increase by increasing alloy elements in weld metal. The weld metal with CE (IIW) value of 0.74 mass% achieved fully overmatching for the X90 pipe. The weld metal yield strength (0.2% offset) was 694 MPa, and the ultimate tensile strength was 833 MPa. It was also confirmed that the reduction of boron in weld metal can improve low temperature toughness of high strength weld metal. Furthermore, it was confirmed that the HAZ has excellent mechanical properties and toughness for riser applications. In this study GSFCAW procedures were also developed. GSFCAW can be used for joining pipe and connector material for riser production welding. The weld metal with a CE (IIW) value of 0.54 mass% could meet the required strength level for X90-grade pipe as specified in ISO 3183. Cross weld tensile testing showed that fractures were achieved in the base metal. Good Charpy impact properties in weld metal and HAZ were also confirmed.

scholarly journals The FN Process-A New Submerged-Arc Welding Process to Improve Toughness of Weld Metal (Report 1)

1964 ◽  
Vol 33 (1) ◽  
pp. 38-54 ◽  
Author(s):  
Tomomichi Hotta ◽  
Toyoaki Bada ◽  
Norio Tanaka ◽  
Izumi Morimoto ◽  
Hiroshi Nakayama
Keyword(s):  
Weld Metal ◽  
Arc Welding ◽  
Welding Process ◽  
Submerged Arc Welding ◽  
Arc Welding Process ◽  
Submerged Arc

Assessment of Heat Affected Zone of Submerged Arc Welding Process through Digital Image Processing

2012 ◽  
Vol 326-328 ◽  
pp. 400-404
Author(s):  
Aniruddha Ghosh ◽  
Somnath Chattopadhyaya ◽  
N.K. Singh
Keyword(s):  
Image Processing ◽  
Digital Image Processing ◽  
Deposition Rate ◽  
Digital Image ◽  
Heat Affected Zone ◽  
Arc Welding ◽  
Welding Process ◽  
Submerged Arc Welding ◽  
High Deposition Rate ◽  
Submerged Arc

Submerged arc welding (SAW) is a high quality, high deposition rate welding process commonly used to join plates of higher thickness in load bearing components. This process of arc welding provides a purer and cleaner high volume weldment that has relatively a higher material deposition rate compared to the traditional welding methods. A common issue in the application of SAW process raises a concern about the uncertainties involved with the heat affected zone (HAZ) in and around the weldment. The most intriguing issue is about HAZ softening that imparts some uncertainties in the welded quality. It increases the probability of fatigue failures at the weakest zones caused by the heating and cooling cycle of the weld zone. An attempt has been made in this paper to assess the heat affected zone of submerged arc welding of structural steel plates through the analysis of the grain structure by means of digital image processing techniques.

A High Notch Toughness Agglomerated Flux for Submerged Arc Welding of Pipeline Steel

2006 ◽  
Vol 306-308 ◽  
pp. 405-410 ◽  
Author(s):  
De Liang Ren ◽  
Bo Liao ◽  
Changling Xu ◽  
Lianhai Hu ◽  
Fu Ren Xiao
Keyword(s):  
Low Temperature ◽  
Weld Metal ◽  
Arc Welding ◽  
High Speed ◽  
Uniform Design ◽  
Welding Process ◽  
Submerged Arc Welding ◽  
Notch Toughness ◽  
Technical Specifications ◽  
Submerged Arc

By using the mathematical uniform design, a new agglomerated flux for high speed and multi-arc submerged arc welding (SAW) has been developed in this paper, which performs excellently in welding process, and the effects of flux composition on the welding characteristics is analyzed as well. The mechanical tests show that the weld metal obtained in SAW with this flux exhibits high toughness at low temperature, and the other mechanical properties of the weld metal also satisfy the technical specifications for the West to East Pipeline Project in China. The microstructures of the weld metal are also examined. Both optical and TEM microphotoes demonstrate that the weld consists mainly of small-sized and uniformly distributed acicular ferrite. These microstructures can effectively prevent the initiation and propagation of micro cracks, resulting in high notch toughness of the weld metal at low temperature.

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