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    SAW Process Variations For CRO

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    Mahesh Deshmukh
    Submerged arc welding has several process variations that can be used for corrosion resistance overlays, including single wire, twin wires, and tandem wires. These variations allow for increased production rates and deposition amounts. Electroslag strip welding and submerged arc strip welding are particularly effective for overlays as they allow high deposition rates of over 50 lbs./hr with low dilution in few layers. The type of welding process used depends on the part size and shape as well as desired deposition rate.

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    SAW Process Variations For CRO

    Uploaded by

    Mahesh Deshmukh
    61 views20 pages
    Submerged arc welding has several process variations that can be used for corrosion resistance overlays, including single wire, twin wires, and tandem wires. These variations allow for increased production rates and deposition amounts. Electroslag strip welding and submerged arc strip welding are particularly effective for overlays as they allow high deposition rates of over 50 lbs./hr with low dilution in few layers. The type of welding process used depends on the part size and shape as well as desired deposition rate.

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    SAW Process Variations for CRO

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    Submerged arc welding has several process variations that can be used for corrosion resistance overlays, including single wire, twin wires, and tandem wires. These variations allow for increased production rates and deposition amounts. Electroslag strip welding and submerged arc strip welding are particularly effective for overlays as they allow high deposition rates of over 50 lbs./hr with low dilution in few layers. The type of welding process used depends on the part size and shape as well as desired deposition rate.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    61 views20 pages

    SAW Process Variations For CRO

    Uploaded by

    Mahesh Deshmukh
    Submerged arc welding has several process variations that can be used for corrosion resistance overlays, including single wire, twin wires, and tandem wires. These variations allow for increased production rates and deposition amounts. Electroslag strip welding and submerged arc strip welding are particularly effective for overlays as they allow high deposition rates of over 50 lbs./hr with low dilution in few layers. The type of welding process used depends on the part size and shape as well as desired deposition rate.

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    © All Rights Reserved
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    Download as pdf or txt
    of 20

    Submerged Arc Welding

    Process Variation

    For Corrosion Resistance Overlays


    Everyone is looking for:

    • Increased production?
    • Increased welding speeds?
    • Increased deposition rates?
    • Reduced base metal dilution?

    2
    Versatility

    • There are many SAW process variations:


    – The size and shape of the part and desired
    deposition rate will help determine the best
    process.

    3
    Deposition rates for CRO
    60
    Deposition - lbs./hr.

    50

    40

    30

    20

    10

    0
    GTAW-HW SAW Wire SAW 30 mm Strip ESW 60 mm Strip
    PROCESS

    4
    Questions?

    • Can your part be positioned to weld in the flat


    position?
    • Can circumferential welds be rotated?

    5
    Process variation

    • Single wire
    • Twin wires/Parallel wires
    • Tandem wires
    – DC/AC, AC/AC
    • SAW strip welding
    • ESW strip welding

    6
    SAW deposition rates

    Single 1 x 4,0 mm DC 8 kg/h


    Twin 2 x 2,5 mm DC 16 kg/h
    Tandem 2 x 4,0 mm DC + AC 22 kg/h
    Tandem Twin 4 x 2,5 mm DC + AC 38 kg/h

    7
    Single wire
    A2S MiniMaster
    A6S ArcMaster A6S ArcMaster Compact
    for 12”

    8
    Single wire

    9
    Twin
    A2T Multitrac A6S Mastertrac

    10
    Single wire vs. Twin wire
    for 4130 build-up
    • Single wire
    o 3/32” wire, 350 amps at 85 ipm, 9.9 lbs./hr.
    • Twin wire
    o 3/32” wire, 600 amps at 85 ipm, 19.8 lbs./hr.

    11
    Tandem Arc
    A6 DS Tandem Master

    A6 DS Tandem Master

    12
    Tandem Arc vs. Single wire

    • Higher currents
    • More than double the deposition rate
    • More penetration & dilution
    • More control of the weld puddle
    • Twice the travel speed
    • Used for joining and would have limited
    overlay applications

    13
    ESW strip

    14
    Process characteristics

    • High deposition rates


    • Low dilution
    • Even penetration
    • Smooth surface
    • High quality deposit
    • Limited to flat position

    15
    Required layers to meet chemistry

    Process Layers Dilution


    • SAW Wire 3 20%
    • SAW Strip 2 15%
    • ESW Strip 1 10%

    16
    Strip Overlay

    The type of welding flux and welding voltage will


    determine the process.

    • Submerged arc strip overlay


    • Uses an arc to melt the strip
    • Requires flux on both sides of strip
    • Has more dilution than ESW
    • Requires two passes to meet chemistry

    17
    Strip Overlay

    • Electroslag strip overlay


    • Welding flux is electrically conductive
    • Low voltage – about 24 volts
    • No welding arc
    • Only requires flux in front of strip
    • Lower dilution
    • Meets chemistry in one pass

    18
    ESW strip overlay

    19
    20

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