Submerged Arc Welding (SAW)

Submerged arc welding (SAW) is a type of arc welding process that is commonly used in heavy-duty industrial applications. This welding process involves the formation of an arc between a continuously-fed electrode and the workpiece. The arc is completely submerged under a layer of granular flux, which helps to protect the weld from atmospheric contamination and also provides additional shielding.

The SAW Process

The SAW process typically involves the following steps:

• Preparing the workpiece: The workpiece must be thoroughly cleaned and prepared before welding can begin. This includes removing any dirt, rust, or other contaminants that could interfere with the welding process.
• Setting up the equipment: The welding equipment, including the power source, wire feeder, electrode, and flux hopper, must be set up and configured for the specific welding job.
• Starting the arc: The arc is started by bringing the electrode into contact with the workpiece, and then slowly lifting it up to create a gap between the two.
• Submerging the arc: Once the arc is established, the flux hopper is activated, and the arc is completely submerged under a layer of granular flux.
• Welding the joint: The electrode is continuously fed into the joint, melting both the electrode and the base metal. As the molten metal cools, it solidifies and forms a bond between the two pieces.

Advantages of SAW

There are several advantages to using SAW for welding applications, including:

• High productivity: SAW is a highly efficient welding process that can be used to weld large, thick sections of metal in a single pass.
• Excellent weld quality: The submerged arc process produces high-quality welds with minimal defects, thanks to the protective layer of flux that helps to prevent contamination and oxidation.
• Good penetration: SAW is capable of penetrating deep into the base metal, resulting in strong, durable welds.
• Reduced fumes and spatter: Because the arc is completely submerged, there is less spatter and fumes generated during the welding process, resulting in a cleaner work environment.

Disadvantages of SAW

While there are many advantages to using SAW for welding applications, there are also some drawbacks to consider, including:

• High setup costs: The equipment and materials required for SAW can be expensive, which may not make it a practical choice for small welding jobs.
• Limited mobility: Because the electrode and flux hopper are fixed in place, SAW is not suitable for welding in tight spaces or in hard-to-reach areas.
• Complex setup: The setup and configuration of the equipment required for SAW can be complex and time-consuming, requiring skilled operators to ensure proper setup and operation.

Applications of SAW

SAW is commonly used in heavy-duty industrial applications, including:

• Shipbuilding
• Structural steel fabrication
• Pipe welding
• Mining equipment
• Pressure vessel fabrication