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Submerged arc welding technology of steel pipe

Attention:     Issuing time:2020-06-18 10:48
Submerged arc welding technology of steel pipe
The most practical steel pipe submerged arc welding technology
The submerged arc welding process is the most ideal choice in the important application fields of pipelines, pressure vessels and tanks, rail manufacturing and major construction. It has the simplest single wire form, double wire structure, series double wire structure and multi wire structure.
The submerged arc welding process can benefit users in many welding applications, from increasing productivity to improving the working environment to ensuring stable quality. Metal processing manufacturing plants that are considering changes to the submerged arc welding process should have thought of many benefits from this process.
Basic knowledge of submerged arc welding
Submerged arc welding process is suitable for heavy industrial applications such as pipelines, pressure vessels and tanks, locomotive manufacturing, heavy construction/digging. It is very suitable for industries that require high productivity, especially those involving very thick materials, and can obtain many benefits from the submerged arc welding process. Its high deposition rate and walking speed can have a significant impact on workers' productivity, efficiency and production costs, which is also one of the key advantages of the submerged arc welding process. Other benefits include: the weld has excellent chemical composition and mechanical properties, minimum arc visibility and lower welding fumes, improved comfort in the working environment, and good weld shape and toe lines.

Submerged arc welding is a wire feeding mechanism that uses a granular flux to separate the arc from the air. As the name suggests, the arc is buried in the flux, which means that when the parameters are set, with the outflow of a layer of flux, the arc is to see missing. The welding wire is continuously fed by the welding torch moving along the welding seam. The arc heat melts a section of welding wire, part of the flux and the base material to form a molten pool, and after condensation forms a weld seam covered with a layer of welding slag. The thickness of the welding material is 1/16"-3/4", which can be 100% penetration welding in a single pass. If the wall thickness is not limited, multiple passes can be welded, and the welding seam is appropriately pretreated and selected. Choose the right flux combination.

Selection of flux and welding wire
Choosing the right flux and wire for a particular submerged arc welding process is critical to using this process to achieve the best results. Although a separate submerged arc welding process is efficient, it can even increase productivity and efficiency based on the welding wire and flux used. The flux not only protects the weld pool, but also helps improve the mechanical properties and productivity of the weld. The formulation of the flux has a huge impact on these factors, affecting current carrying capacity and slag release. Current-carrying capacity means that the highest possible deposition efficiency and high-quality weld profile can be obtained. The slag release of a specific flux affects the choice of flux, because some fluxes are more suitable for certain welding designs than others.
Flux selection options for submerged arc welding include active and neutral types of welding. One basic difference is that active flux changes the chemical properties of the weld, while neutral flux does not. The active flux is characterized by containing silicon and manganese. These elements help to maintain the tensile strength of the weld under higher heat input, help the weld to remain smooth and provide good slag release capability at higher travel speeds. In general, active flux can help reduce the risk of poor soldering quality, as well as expensive post-weld cleaning and rework. But remember, active flux is usually best for single pass or double pass welding. Neutral fluxes are better for large multi-pass welding because they help avoid the formation of brittle, crack-sensitive welds.

There are many choices of wire for submerged arc welding, each with advantages and disadvantages. Some welding wires are formulated for welding at higher heat inputs, while other welding wires are specifically designed with alloys that help the flux clean the welding. Please note that the interaction between the chemical nature of the welding wire and the heat input affects the mechanical properties of the weld. The choice of filler metal can also greatly improve productivity. For example, using a metal-cored wire with a submerged arc welding process can increase the deposition efficiency by 15% to 30% compared to using a solid wire, while also providing a wider, shallower penetration profile. Due to its high travel speed, the metal-cored wire can also reduce heat input to minimize the risk of welding deformation and burn-through. If in doubt, consult the filler metal manufacturer to determine which welding wire and flux combination is best for a particular application.

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