Submerged Arc Welding Technical Handbook - Esab
Submerged Arc Welding Technical Handbook - Esab Submerged Arc Welding Technical Handbook - Esab
- - Product documents Product Data Sheet OK Flux 10.72 S 'Submerged arc welding' Product Data Sheet OK Autrod 12.22 S 'Submerged arc welding' Signed by Approved by Reg no Cancelling Reg date Page Lars Andersson Martin Gehring/Christos Skodras EN003642 EN003239 2006-11-03 1 (1) REASON FOR ISSUE Approvals: CE and NAKS added, Ü deleted. Signed by Approved by Reg no Cancelling Reg date Page GENERAL Lars Andersson Martin Gehring/Christos Skodras EN003718 EN000925 2006-11-07 1 (2) REASON FOR ISSUE All data revised. New layout. Copper-coated, unalloyed wire for Submerged Arc Welding. Suitable in combination with most fluxes. Increased Si content and thus especially suitable for neutral fluxes (e.g.: OK Flux 10.62) or in order to increase the fluidity of the molten pool. For structural steels, ship building steels, pressure vessel steels, fine Signed by Approved by Reg no Cancelling Reg date Page Product Data Sheet OK Flux 10.72/OK Autrod 12.22 GENERAL grained steels, etc. CLASSIFICATIONS Wire Electrode EN 756 S2Si SFA/AWS A5.17 EM12K REASON FOR ISSUE Agglomerated aluminate-basic flux for Submerged Arc Welding especially for applications with toughness requirements at low temperature. Excellent slag removal also in narrow V-joints. For wind tower productions, pressure vessels, general constructions etc. Extremely high current carrying capacity. For single or multi wire procedures. Suitable for DC and AC welding. Single layer and multi layer welding of unlimited plate thickness. Lars Andersson Martin Gehring/Christos Skodras EN003973 EN003224 2007-06-22 1 (2) S 'Submerged arc welding' Mechanical Properties of Weld Metal rearranged, Approvals updated (Ü deleted; CE added), General description slightly modified. CLASSIFICATIONS Flux EN 760 SA AB 1 57 AC H5 GENERAL APPROVALS CE EN 13479 DB 51.039.12 Comments: All others: See Flux-Wire combinations CHEMICAL COMPOSITION APPROVALS Agglomerated aluminate-basic flux-wire-combination for Submerged Arc Welding. Especially for applications with toughness requirements down to -50°C. Excellent slag removal also in narrow V-joints. For structural steels, fine grained steels, pressure vessel steels, low temperature steels, etc. Especially for wind tower CE EN 13479 productions. Extremely high current carrying capacity. For single or multi wire procedures. Suitable for DC and AC welding. Single layer and multi layer welding of unlimited plate thickness. SLAG TYPE Aluminate-basic CHEMICAL COMPOSITION Flux (%) Nom Al2O3+MnO CaF2 CaO+MgO SiO2+TiO2 30 20 25 20 CLASSIFICATIONS Flux EN 760 SA AB 1 57 AC H5 CLASSIFICATIONS Weld Metal (as welded) EN 756 S 38 5 AB S2Si SFA/AWS A5.17 F7A8-EM12K CLASSIFICATIONS Weld Metal (PWHT) SFA/AWS A5.17 F6P8-EM12K C Si Mn P S Wire/Strip (%) Min Max 0.08 0.12 0.15 0.30 0.90 1.15 0.015 0.020 APPROVALS DB 52.039.05 NAKS/HAKC 2,5 - 3,2 mm: CZ Sepros UNA 347719 Comments: All others: See Flux-Wire combinations CLASSIFICATIONS Wire Electrode EN 756 S2Si SFA/AWS A5.17 EM12K CHEMICAL COMPOSITION CE EN 13479 DB 51.039.12 - 52.039.05 VdTÜV 10084 Other properties: Alloy Transfer Basicity (Boniszewski) nom: 1.9 Bulk Density Grain Size Hydrogen WELDING POLARITY DC+, AC C Si Mn P S No Silicon and moderately Manganese alloying Max Nom 0.05 0.3 1.5 0.03 0.02 nom: 1.2 kg/dm3 0.2-1.6 mm (10x65 mesh) max 5 ml H/100g weld metal (Redried flux) FLUX CONSUMPTION DC+, 580A, 29V AC, 580A, 29V Max Nom (kg Flux / kg Wire/Strip) Arc Voltage DC+ AC 26 0.7 0.6 30 1.0 0.9 34 1.3 1.2 38 1.6 1.4 Current (A): 580 Travel Speed (cm/min): 55 Dimension (mm): Ø4.0 0.03 0.02 All Weld Metal (%) Wire/Strip (%) 0.06 0.3 1.4 Min Max 0.08 0.12 0.15 0.30 0.90 1.15 0.015 0.020 All fluxes, wires and flux/wire combinations are supported by core documentation such as product data sheets (PDS) and safety data sheets (SDS) 64
The submerged arc welding process Submerged arc welding (SAW) is a method in which the heat required to fuse the metal is generated by an arc formed by an electric current passing between the electrode and the workpiece. A layer of granulated mineral material known as submerged arc welding flux covers the tip of the welding wire, the arc, and the workpiece. There is no visible arc and no sparks, spatter or fume. The electrode may be a solid or cored wire or a strip. SAW is normally a mechanised process. The welding current, arc voltage, and travel speed all affect the bead shape, depth of penetration and chemical composition of the deposited weld metal. Since the operator cannot observe the weld pool, great reliance is placed on parameter setting and positioning of the electrode. General scope: range between 100 and 3600 amps The welding operation When the apparatus is set into operation, several things occur in quick sequence: through the hopper tube and continuously distributes itself over the seam a short distance ahead of the welding zone. feed the welding wire into the joint at a controlled rate current flows between the electrode and the work. automatically) to travel along the seam. The tremendous heat evolved by the passage of the electric current through the welding zone melts the end of the wire and the adjacent edges of the work-pieces, creating a pool of molten metal. The submerged arc welding flux completely shields the welding zone from contact with the atmosphere. As the welding zone moves along the joint, the fused submerged arc welding flux cools and hardens into a brittle, glass-like material which protects the weld until cool, then usually detaches itself completely from the weld. Benefits deep and safe penetration Limitations during welding possible Equipment – Basic Principles The high welding speeds and deposition rates which are characteristic of submerged arc welding require automatic control of the motor that feeds the welding wire into the weld. No manual welder could smoothly deposit welding wire at speeds comparable to those of a submerged arc welding machine. Nor could he maintain the same precise control of welding parameters. The automatic control and power supply system used in submerged arc welding operates to maintain a constant voltage and current. Relationship of welding voltage to distance between welding wire and work-piece The welding voltage is proportional to the length of the current path between the welding wire and work-piece: work-piece increases, the welding voltage will increase. work-piece decreases, the welding voltage will decrease. 65
- Page 13 and 14: Flux selection by wire type Wire EN
- Page 15 and 16: How to choose the right flux-wire c
- Page 17 and 18: OK Flux 10.30 - High recovery flux
- Page 19 and 20: OK Flux 10.45 - Fused flux for very
- Page 22 and 23: OK Flux 10.47 & OK Tubrod 15.24S ba
- Page 24 and 25: OK Flux 10.61 - High basic flux for
- Page 26 and 27: OK Flux 10.62 - High impact flux fo
- Page 29 and 30: Narrow gap welding - complete ESAB
- Page 31 and 32: OK Flux 10.69 - Backing flux for on
- Page 33 and 34: pt Wiehltal highway bridge, Germany
- Page 35 and 36: Typical weld metal chemical composi
- Page 38 and 39: OK Flux 10.72 - Wind towers, pressu
- Page 40 and 41: OK Flux 10.74 - Pipemill flux for l
- Page 42 and 43: OK Flux 10.76 - For high dilution a
- Page 44 and 45: OK Flux 10.78 - Welding on rust and
- Page 46 and 47: OK Flux 10.81 - For smooth weld bea
- Page 48 and 49: OK Flux 10.81 - For power generatio
- Page 50 and 51: OK Flux 10.87 - High speed flux wit
- Page 52 and 53: OK Flux 10.88 - High tolerance for
- Page 54 and 55: OK Flux 10.90 - Flux for 9% Ni and
- Page 56 and 57: OK Flux 10.92 - All-purpose flux fo
- Page 58 and 59: OK Flux 10.93 - ESAB’s number one
- Page 60 and 61: OK Flux 10.94 - An efficient techni
- Page 62 and 63: OK Grain 21.85 - Metal powder addit
- Page 66 and 67: work-piece remains constant, the we
- Page 68 and 69: SAW variants Cored Wire Single Wire
- Page 70 and 71: Neutral, active or alloying fluxes
- Page 72 and 73: Agglomerated and fused fluxes Agglo
- Page 74 and 75: Automation Welding automation gives
- Page 76 and 77: Handling equipment ESAB wire condui
- Page 78 and 79: R&D and Central Laboratory ESAB Cen
- Page 80 and 81: SAW joint preparations Stainless st
- Page 82 and 83: Trouble shooting guide, ctd. Defect
- Page 84 and 85: A suitable spool for each applicati
- Page 86 and 87: Always the most productive delivery
- Page 88 and 89: Classification Standards EN 756 Gui
- Page 90 and 91: SFA/AWS A5.23: SPECIFICATION FOR LO
- Page 92 and 93: EN ISO 18274: WELDING CONSUMABLES -
- Page 94: Approvals Approvals from marine soc
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Product documents<br />
Product Data Sheet OK Flux 10.72<br />
S '<strong>Submerged</strong> arc welding'<br />
Product Data Sheet OK Autrod 12.22<br />
S '<strong>Submerged</strong> arc welding'<br />
Signed by Approved by Reg no Cancelling Reg date Page<br />
Lars Andersson Martin Gehring/Christos Skodras EN003642 EN003239 2006-11-03 1 (1)<br />
REASON FOR ISSUE<br />
Approvals: CE and NAKS added, Ü deleted.<br />
Signed by Approved by Reg no Cancelling Reg date Page<br />
GENERAL<br />
Lars Andersson Martin Gehring/Christos Skodras EN003718 EN000925 2006-11-07 1 (2)<br />
REASON FOR ISSUE<br />
All data revised. New layout.<br />
Copper-coated, unalloyed wire for <strong>Submerged</strong> <strong>Arc</strong> <strong>Welding</strong>. Suitable in combination with most fluxes.<br />
Increased Si content and thus especially suitable for neutral fluxes (e.g.: OK Flux 10.62) or in order to<br />
increase the fluidity of the molten pool. For structural steels, ship building steels, pressure vessel steels, fine<br />
Signed by Approved by Reg no Cancelling Reg date Page<br />
Product Data Sheet OK Flux 10.72/OK Autrod 12.22<br />
GENERAL<br />
grained steels, etc.<br />
CLASSIFICATIONS Wire Electrode<br />
EN 756 S2Si<br />
SFA/AWS A5.17 EM12K<br />
REASON FOR ISSUE<br />
Agglomerated aluminate-basic flux for <strong>Submerged</strong> <strong>Arc</strong> <strong>Welding</strong> especially for applications with toughness<br />
requirements at low temperature. Excellent slag removal also in narrow V-joints. For wind tower productions,<br />
pressure vessels, general constructions etc. Extremely high current carrying capacity. For single or multi wire<br />
procedures. Suitable for DC and AC welding. Single layer and multi layer welding of unlimited plate thickness.<br />
Lars Andersson Martin Gehring/Christos Skodras EN003973 EN003224 2007-06-22 1 (2)<br />
S '<strong>Submerged</strong> arc welding'<br />
Mechanical Properties of Weld Metal rearranged, Approvals updated (Ü deleted; CE added), General<br />
description slightly modified.<br />
CLASSIFICATIONS Flux<br />
EN 760<br />
SA AB 1 57 AC H5<br />
GENERAL<br />
APPROVALS<br />
CE EN 13479<br />
DB 51.039.12<br />
Comments: All others: See Flux-Wire combinations<br />
CHEMICAL COMPOSITION<br />
APPROVALS<br />
Agglomerated aluminate-basic flux-wire-combination for <strong>Submerged</strong> <strong>Arc</strong> <strong>Welding</strong>. Especially for applications<br />
with toughness requirements down to -50°C. Excellent slag removal also in narrow V-joints. For structural<br />
steels, fine grained steels, pressure vessel steels, low temperature steels, etc. Especially for wind tower<br />
CE EN 13479<br />
productions. Extremely high current carrying capacity. For single or multi wire procedures. Suitable for DC and<br />
AC welding. Single layer and multi layer welding of unlimited plate thickness.<br />
SLAG TYPE<br />
Aluminate-basic<br />
CHEMICAL COMPOSITION<br />
Flux (%)<br />
Nom<br />
Al2O3+MnO<br />
CaF2<br />
CaO+MgO<br />
SiO2+TiO2<br />
30<br />
20<br />
25<br />
20<br />
CLASSIFICATIONS Flux<br />
EN 760 SA AB 1 57 AC H5<br />
CLASSIFICATIONS Weld Metal (as welded)<br />
EN 756 S 38 5 AB S2Si<br />
SFA/AWS A5.17 F7A8-EM12K<br />
CLASSIFICATIONS Weld Metal (PWHT)<br />
SFA/AWS A5.17 F6P8-EM12K<br />
C<br />
Si<br />
Mn<br />
P<br />
S<br />
Wire/Strip (%)<br />
Min Max<br />
0.08 0.12<br />
0.15 0.30<br />
0.90 1.15<br />
0.015<br />
0.020<br />
APPROVALS<br />
DB 52.039.05<br />
NAKS/HAKC 2,5 - 3,2 mm: CZ<br />
Sepros UNA 347719<br />
Comments: All others: See Flux-Wire combinations<br />
CLASSIFICATIONS Wire Electrode<br />
EN 756 S2Si<br />
SFA/AWS A5.17 EM12K<br />
CHEMICAL COMPOSITION<br />
CE EN 13479<br />
DB 51.039.12 - 52.039.05<br />
VdTÜV 10084<br />
Other properties:<br />
Alloy Transfer<br />
Basicity (Boniszewski) nom: 1.9<br />
Bulk Density<br />
Grain Size<br />
Hydrogen<br />
WELDING POLARITY<br />
DC+, AC<br />
C<br />
Si<br />
Mn<br />
P<br />
S<br />
No Silicon and moderately Manganese alloying<br />
Max Nom<br />
0.05<br />
0.3<br />
1.5<br />
0.03<br />
0.02<br />
nom: 1.2 kg/dm3<br />
0.2-1.6 mm (10x65 mesh)<br />
max 5 ml H/100g weld metal (Redried flux)<br />
FLUX CONSUMPTION<br />
DC+, 580A, 29V AC, 580A, 29V<br />
Max Nom<br />
(kg Flux / kg Wire/Strip)<br />
<strong>Arc</strong> Voltage DC+ AC<br />
26 0.7 0.6<br />
30 1.0 0.9<br />
34 1.3 1.2<br />
38 1.6 1.4<br />
Current (A): 580<br />
Travel Speed (cm/min): 55<br />
Dimension (mm): Ø4.0<br />
0.03<br />
0.02<br />
All Weld Metal (%) Wire/Strip (%)<br />
0.06<br />
0.3<br />
1.4<br />
Min Max<br />
0.08 0.12<br />
0.15 0.30<br />
0.90 1.15<br />
0.015<br />
0.020<br />
All fluxes, wires and flux/wire combinations are supported<br />
by core documentation such as product data sheets<br />
(PDS) and safety data sheets (SDS)<br />
64
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