Submerged Arc Welding Technical Handbook - Esab
Submerged Arc Welding Technical Handbook - Esab Submerged Arc Welding Technical Handbook - Esab
SAW joint preparations Stainless steels Type of joint 1 2 Plate thickness mm Wire diameter mm Run No. Welding current A Arc voltage V 6 2.4 1 300 33 40 2.4 2 400 34 40 3.2 1 400 34 100 3.2 2 500 34 130 8 2.4 1 350 33 40 2.4 2 450 34 40 3.2 1 450 34 55 3.2 2 550 34 55 4 1 450 34 100 4 2 550 34 130 Welding speed cm/min 60 1.3 2 2 gap: 0-2 mm 10 2.4 1 420 30 45 2.4 2 420 32 40 2.4 3 420 32 40 3.2 1 500 30 55 3.2 2 500 32 55 4 1 550 31 65 4 2 550 34 100 12 4 1 600 32 60 4 2 600 34 80 20 4 1 575 31 60 4 2 600 32 60 4 3-5 600 34 65 60 gap: 20-2 mm mm 1.4 2 2.3 25 4 1 550 32 60 4 2 600 34 50 4 3 600 34 50 4 4-8 600 34 60 90 2 6 2 1-n 300 31 60 10 3.2 1-n 380 32 65 16 3.2 1-n 450 34 70 70 5 8 4 1 450 32 90 4 2 550 34 85 10 4 1 500 32 65 4 2 600 34 85 70 5 12 4 1 500 32 60 4 2 600 34 70 14 4 1 550 32 60 4 2 600 34 60 80
Trouble shooting guide Defect Possible causes Remedies Porosity Rusty plate Wire brush or grind plate Oily plate Contaminated plate Wet plate Primer Flux cover too shallow, arc flashes Wet flux Magnetic arc blow Flux becomes too fine Defective root run with MMA Degrease or preheat Use active flux or killed wire Preheat plate Remove primer Increase flux feeding Dry flux according to instructions on bag Weld towards earth clamp or split earth and attach at ends Add at least 1 part new flux to 3 parts of recycled flux Weld defect free root run; possibly change to MAG Undercut Arc blow Weld towards earth clamp or split earth and attach at ends Welding speed too high Wire alignment incorrect Voltage too high Adjust welding parameters Adjust alignment Reduce voltage Slag sticking Voltage too high Reduce voltage Current too high Poor weld bead profile Hot plate Incorrect joint preparation Excessive reinforcement Welding speed too low Current too high Reduce current Adjust welding parameters Check interpass temperature Modify joint preparation Increase welding speed Decrease current Burn through Current too high Reduce current Poor fit-up Root face too small Welding speed too low Adjust fit-up Increase root face Increase welding speed Weld metal running Rotation of work piece too slow Increase rotation speed Incorrect wire position Too high voltage/current Flux too fluid Adjust position Decrease voltage/current Check flux selection Longitudinal cracks Convex reinforcement Adjust welding parameters Elongated weld pool Poor fit-up Wrong consumable selection Weld depth to width ratio > 1 Weld metal hydrogen Decrease welding speed Reduce root gap Refer to ESAB Adjust welding parameters Reduce all possibilities for hydrogen occurrence Insufficient penetration and excessive reinforcement; also misaligned. Weld depth to width ratio > 1 and relatively large amount of impurities in base material (S, P, Nb). 81
- 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 64 and 65: - - Product documents Product Data
- 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 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
SAW joint preparations<br />
Stainless steels<br />
Type of joint<br />
1<br />
2<br />
Plate thickness<br />
mm<br />
Wire diameter<br />
mm<br />
Run No.<br />
<strong>Welding</strong><br />
current A<br />
<strong>Arc</strong> voltage<br />
V<br />
6 2.4 1 300 33 40<br />
2.4 2 400 34 40<br />
3.2 1 400 34 100<br />
3.2 2 500 34 130<br />
8 2.4 1 350 33 40<br />
2.4 2 450 34 40<br />
3.2 1 450 34 55<br />
3.2 2 550 34 55<br />
4 1 450 34 100<br />
4 2 550 34 130<br />
<strong>Welding</strong> speed<br />
cm/min<br />
60<br />
1.3<br />
2<br />
2<br />
gap: 0-2 mm<br />
10 2.4 1 420 30 45<br />
2.4 2 420 32 40<br />
2.4 3 420 32 40<br />
3.2 1 500 30 55<br />
3.2 2 500 32 55<br />
4 1 550 31 65<br />
4 2 550 34 100<br />
12 4 1 600 32 60<br />
4 2 600 34 80<br />
20 4 1 575 31 60<br />
4 2 600 32 60<br />
4 3-5 600 34 65<br />
60<br />
gap: 20-2 mm mm<br />
1.4<br />
2<br />
2.3<br />
25 4 1 550 32 60<br />
4 2 600 34 50<br />
4 3 600 34 50<br />
4 4-8 600 34 60<br />
90<br />
2<br />
6 2 1-n 300 31 60<br />
10 3.2 1-n 380 32 65<br />
16 3.2 1-n 450 34 70<br />
70<br />
5<br />
8 4 1 450 32 90<br />
4 2 550 34 85<br />
10 4 1 500 32 65<br />
4 2 600 34 85<br />
70<br />
5<br />
12 4 1 500 32 60<br />
4 2 600 34 70<br />
14 4 1 550 32 60<br />
4 2 600 34 60<br />
80
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