Different definitions
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1. Manual arc welding
Manual arc welding, for short, is a welding method that uses a manually operated welding rod and the workpiece to be welded as two electrodes, and uses the arc heat between the welding rod and the welding piece to melt the metal.
2. Submerged arc automatic welding
Different characteristics
1. Manual arc welding
'The equipment is simple.
'Flexible and convenient operation.
'Can perform all-position welding and is suitable for welding a variety of materials.
'The disadvantages are low production efficiency and high labor intensity.
2. Submerged arc automatic welding
'High productivity.
'High quality and beautiful welding seams.
'Improving working conditions. The mechanized operation of the welding process is more convenient, with less smoke and dust, and no arc radiation.
Welding electricity protection measures
1. Before welding work, check whether the welding machine equipment and tools are safe and reliable. For example, whether the shell of the welding machine is grounded, whether the connection points of the welding machine are in good contact, whether the insulation of the welding cable is damaged, etc. It is not allowed to start operations without carrying out safety checks.
2. The welder's hands and body are not allowed to touch the conductors of the secondary circuit casually, and they are not allowed to rely on the workbench, welding parts, or come into contact with electrified objects such as welding clamps. For welding operations where the no-load voltage of the welding machine is high, and when operating in humid working locations, rubber insulating mats should also be laid on the ground near the operating platform.
3. The following operations should be performed after cutting off the power switch: moving the working location, moving the welding machine; replacing fuses; repairing the welding machine when it fails; changing the welding machine joints; changing the welding parts and modifying the layout of the secondary circuit, etc. When pushing and pulling the switch, insulating gloves must be worn; at the same time, the welder's head should be tilted to prevent arc sparks from burning the face.
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4. When welding in metal containers, on metal structures, and other small workplaces, the risk of electric shock is greatest, and special protective measures must be taken. For example, use rubber mats, wear leather gloves, and wear insulated shoes.
5. Welding operators are not allowed to use themselves or the transmission parts of machinery and equipment as welding circuits under any circumstances, and it is strictly prohibited to use the metal structure of the factory, rails (pipes) and other access lines as conductors.
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The grounding protection device of the welding machine must be complete and effective. At the same time, the welding machine must be equipped with a no-load automatic power-off protection device.7. There should be no joints in the middle of the welding cable. If it is necessary to use short wires to extend the length, there should be no more than 2 joints. The joints should be made of copper material and ensure good insulation.
8. Strengthen personal protection. Personal protective equipment for welders includes intact work clothes, insulating gloves, overshoes, etc.
9. The installation, inspection and repair of electric welding equipment must be carried out by electricians, and temporary construction sites should be connected to the power supply by electricians.
The submerged arc welding (SAW) process has the potential to substantially improve deposition rates and productivity and to provide repeatable weld quality. However, it is better-suited for some applications than others.
If you are thinking about using SAW, consider the numerous factors that affect process success. Material thickness, joint design, fit-up, and length all need to be assessed.
Also, be aware that achieving maximum success with SAW requires some homework and an investment in equipment upfront, but the investment can yield a significant and quick return in many case.
Single-wire applications can achieve deposition rates of up to 18 kilograms per hour, depending on wire size, type, and polarity. While achieving this value is not typical for most applications, it can be quite easy to use SAW to improve deposition rates over a current GMAW, flux-cored arc welding (FCAW), or shielded metal arc welding (SMAW, or stick) process. Welding equipment and filler metal manufacturers can assist you in determining starting parameters and provide insight on improvement potential.
In addition to productivity gains, the process can provide repeatable weld quality. SAW is almost exclusively a mechanized process. The arc and/or work-motion machinery maintains consistent travel speeds and torch positioning, so operators with less hands-on welding experience can easily oversee it. Companies can then allocate their most skilled personnel in the most demanding areas of the operation.
The process also offers an improved working environment because it has low fume generation and no visible arc. This minimizes UV exposure, so you do not need to wear a helmet or welding jacket, and it's easier for other tasks to occur near the welding operation in progress.
SAW produces excellent mechanical properties in the finished weld. Many medium- to high-basicity wire/flux combinations can obtain high toughness. Certain SAW wires and fluxes can also help to maintain properties at high heat inputs, further optimizing potential deposition rates.
Several factors make a part right for SAW. Material type and thickness are two important considerations.
SAW is best-suited for carbon and low-alloy steels, but it can be used for stainless steel and nickel-based alloys as well. And while SAW of thick materials is the most common, it is a misconception that the process can be used only on thick material
SAW is used successfully on thin materials in many applications, such as propane tanks and water heaters. Although high amperage are used, the travel speed increases significantly in these cases so that the resulting heat input is low, depending on joint design. Note that welding thinner materials also requires greater attention to the 'smoothness' of the mechanization, joint tracking, and consistency of joint preparation. Joint backing using copper and/or welding flux is a popular choice for improved repeatability.
SAW is suited to straight-line joints, since parts with jogs in the weld require more complex and expensive mechanization to handle repeatedly. And while SAW is well-suited for high-volume components, that doesn't mean it is restricted to the exact same part over and over. Even job shops can take advantage of the technology. Parts don't need to be identical, but they should have similar geometries to maximize the process. For example, it's common for SAW and equipment to easily weld both 3.7-meter-diameter and 3-m-dia. pressure vessels since the geometries are similar. The idea is to find parts that can use the same arc and work motion equipment and placement to minimize changeover and, therefore, downtime.
A disadvantage of SAW is the required interpass cleaning. For this reason, it's better-suited to long weld joints (often 1.2 m or longer), which can be cleaned during welding. With shorter welds, the total amount of time spent cleaning is greater because multitasking is more difficult, and the ratio of arc-on time to time spent repositioning and readjusting equipment becomes smaller. As a side note, it is also important to consider investing in flux recovery and reconditioning equipment (a vacuum and oven) to minimize consumable costs.
SAW is a popular choice in pressure vessel and pipe applications, because the vessel or pipe can be rotated on positioners. But below 200 mm dia. flux containment becomes more difficult because the flux waterfalls off the pipe. Because the weld cooling rate in SAW is slower than in other processes, using it on smaller-diameter pipe can also result in an unacceptable bead profile and repair rates.
SAW equipment is bulky, which makes space and part access key considerations. A system may need to be custom-designed for use in smaller spaces, but wire feeding may become an issue. The large diameters simply aren't as flexible as the small diameters used on a robotic GMAW arm.
Return on Investment.
The SAW process can provide significant advantages for productivity and quality in the right application. However, it's important to have a good understanding of what the process involves, and make sure your specific application is well-suited to SAW before making the investment.
Integrator and equipment manufacturers can offer help in design and implementation of an optimized SAW process, or advise when SAW may not be the right process. In certain applications, the impact on the bottom line can be significant.
These are a preliminary review over the topic. if you feel this is help full. Please be free to add value here by sharing your experience and knowledge on the topic in the comment box below.
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Muhsin.O.V
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