Professional Documents
Culture Documents
By
L D Poyyara
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SAW
Fusion Welding Process
Automatic / Semi Automatic
Arc Between Consumable Electrode And Work
Arc Covered Under granular Flux
Wire / Electrode Continuously Fed To Weld Pool
Wire / Arc Under Flux Moves Along The Groove
Wire, BM & Flux Close to Arc Melt Under Flux
On Cooling Weld Metal Solidifies
Molten Flux Forms Thick Slag
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Coating On Weld
SAW
Hopper
Wire +
+
Slag
Flux Weld
Base Metal
Arc
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Flux For SAW
Sodium Chloride
Potassium Chloride
Titanium Dioxide
Sodium Silicate
Deoxidizing Agents
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Types Of Flux
Fused Flux
Agglomerated Flux
Neutral Flux
Active Flux
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Types Of Flux
Neutral Flux
-Wire compatible to base metal
- Single flux suitable for several material
Active Flux
- Single flux suitable for specific application
- Wire may be different from basemetal
- To be welded within the recommended parameters
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Function Of Flux In SAW
Stabilizes Arc
Prevents contamination of weld metal
Cleans the weld from unwanted impurities
Increases Fluidity of molten metal
Generates inert gas shielding while metal transfers
Forms slag after melting & covers weld
Allows deposited metal to cool slowly
Compensates alloying elements Within the weld
Eliminates spatter generation
Helps in even & uniform bead finish
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Baking Requirements For Flux
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Why Baking Flux?
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How Does Moist Flux Generate
Crack Within Weld?
Moist Flux introduce atomic hydrogen at high
temperature in weld
On cooling, atomic hydrogen try to form
molecules
The reaction results in stresses and fine cracks
Cracks occur within hardened metal - HAZ
Known as Hydrogen Embrittlement or Under
Bead Crack or Delayed Crack
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Reuse Of Flux
Thyrester DC
Rectifier DC
Motor Generator DC
Transformer - AC
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Characteristic Of Power Source
Machine welding
Drooping Cons. A Linear Cons. V
V V
V1
V1
V2
V2
A A
A1 A2 A1 A2
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SAW Wire - Electrode
Consumable Electrode / Wire
Layer Wound On Spool / Coil
CS & LAS Wires Coated with Cu
Conducts Current and generates Arc
Chemistry Compatible To Base Metal
Grade Of Flux Can Be Same For CS & LAS
Wire melts & deposited as filler in joint
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Typical Welding Parameter
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Important Terminology used in
Critical SAW
Preheating
Post Heating or Dehydrogenation
Intermediate Stress leaving
Inter pass Temperature
Post Weld Heat Treatment
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What Is Preheating?
Heating the base metal along the weld joint
to a predetermined minimum temperature
immediately before starting the weld.
Heating by Oxy fuel flame or electric
resistant coil
Heating from opposite side of welding
wherever possible
Temperature to be verified by thermo chalks
prior to starting the weld
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Why Preheating?
Preheating eliminates possible cracking of weld
and HAZ
Applicable to
-Hardenable low alloy steels of all thickness
-Carbon steels of thickness above 25 mm.
-Restrained welds of all thickness
Preheating temperature vary from 75C to 200C
depending on hardenability of material, thickness
& joint restrain
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How does Preheating Eliminate
Crack?
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What Is Post Heating?
Raising the pre heating temperature of the weld
joint to a predetermined temperature range (250
C to 350 C) for a minimum period of time (3 Hrs)
before the weld cools down to room temperature.
Post heating performed when welding is completed
or terminated any time in between.
Heating by Oxy fuel flame or electric resistant coil
Heating from opposite side of welding wherever
possible
Temperature verified by thermo chalks during the
period
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Why Post Heating?
Post heating eliminates possible delayed
cracking of weld and HAZ
Applicable to
-Thicker hardenable low alloy steels
-Restrained hardenable welds of all
thickness
Post heating temperature and duration
depends on hardenability of material,
thickness & joint restrain
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How does Post Heating Eliminate
Crack?
SAW introduces hydrogen in weld metal
Entrapped hydrogen in weld metal induces
delayed cracks unless removed before
cooling to room temperature
Retaining the weld at a higher temperature
for a longer duration allows the hydrogen to
come out of weld
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What Is Intermediate Stress
Relieving?
Heat treating a subassembly in a furnace to
a predetermined cycle immediately on
completion of critical restrained weld joint /
joints without allowing the welds to go down
the pre heat temperature. Rate of heating,
Soaking temperature, Soaking time and rate
of cooling depends on material quality and
thickness
Applicable to
Highly restrained air hardenable material
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Why Intermediate Stress
Relieving?
Restrained welds in air hardenable steel
highly prone to crack on cooling to room
temperature.
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What Is Post Weld Heat
Treatment?
Heat treating an assembly on completion of
all applicable welding, in an enclosed
furnace with controlled heating/cooling rate
and soaking at a specific temperature for a
specific time.
Rate of heating, Soaking temperature,
Soaking time and rate of cooling depends on
material quality and thickness
Applicable to
-All type of CS & LAS
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Why Post Weld Heat Treatment?
Welded joints retain internal stresses within
the structure
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