{"id":20809,"date":"2023-02-01T14:56:13","date_gmt":"2023-02-01T12:56:13","guid":{"rendered":"https:\/\/fractory.com\/?p=20809"},"modified":"2024-08-09T14:40:37","modified_gmt":"2024-08-09T11:40:37","slug":"submerged-arc-welding-explained","status":"publish","type":"post","link":"https:\/\/fractory.com\/submerged-arc-welding-explained\/","title":{"rendered":"Submerged Arc Welding (SAW) Explained"},"content":{"rendered":"<p data-pm-slice=\"1 3 []\">Submerged arc welding is a standard industrial process wherein an arc is formed between a workpiece and an electrode. It was invented in 1935 by the E. O. Paton Electric Welding Institute in Kyiv, Ukraine as a driving force behind the Second World War. One of the most notable applications of this invention is the <a href=\"https:\/\/en.wikipedia.org\/wiki\/T-34\" target=\"_blank\" rel=\"noopener\">T34 military tank<\/a>.<\/p>\n<p>While this <a href=\"https:\/\/fractory.com\/types-of-welding-processes\/\">welding technology<\/a> has been around for almost a century, it is still an essential choice for many industries.<\/p>\n    <div class=\"shortcode-key-takeaways\">\n        <span class=\"v2-section-title v2-section-title--md\">Key Takeaways<\/span>\n        <ul class=\"shortcode-key-takeaways-list\">\n                                                <li>Submerged Arc Welding (SAW) uses a <strong>blanket of flux<\/strong> to protect the weld from contamination, producing high-quality, consistent welds with minimal spatter.<\/li>\n                                                                <li>SAW is particularly effective for welding <strong>thick, flat, or horizontal metal sections<\/strong>, commonly used in industries like shipbuilding, automotive, and railways.<\/li>\n                                                                <li>The process is efficient, allowing for <strong>deep weld penetration<\/strong> and <strong>high deposition rates<\/strong>, making it suitable for both indoor and outdoor applications.<\/li>\n                                                                <li>SAW is <strong>unsuitable for vertical or overhead positions<\/strong>, and is best for <strong>simpler geometries<\/strong>. <\/li>\n                                                                                                                                                                                                            <\/ul>\n    <\/div>\n    \n<h2>What Is Submerged Arc Welding?<\/h2>\n<p>Submerged arc welding (SAW) is a welding method where similarly to other arc welding processes, the base metals are joined by forming an electric arc between the workpiece and an electrode.<\/p>\n<p>SAW process&#8217;s defining element is how it protects the weld metal from atmospheric contamination. <strong>Submerged arc welding uses a powdered flux layer, generating shielding and slag while creating a smooth and clean weld.<\/strong> Other methods use shielding gas (<a href=\"https:\/\/fractory.com\/mig-vs-tig-welding\/\">MIG\/TIG welding<\/a>), flux-cored wire (<a href=\"https:\/\/fractory.com\/flux-cored-arc-welding-explained\/\">FCAW<\/a>), flux-coated electrode (<a href=\"https:\/\/fractory.com\/shielded-metal-arc-welding\/\">SMAW<\/a>), or controlled environment (<a href=\"https:\/\/fractory.com\/plasma-arc-welding-paw-explained\/\">plasma welding<\/a>) for protecting the weld.<\/p>\n<h2>How Does the Submerged Arc Welding Process Work?<\/h2>\n<p><img decoding=\"async\" class=\"aligncenter size-full wp-image-20826\" src=\"https:\/\/fractory.com\/wp-content\/uploads\/2023\/02\/sub-arc-welding-equipment-4.jpg\" alt=\"welding thick metal sheets with SAW process\" width=\"800\" height=\"533\" srcset=\"https:\/\/fractory.com\/wp-content\/uploads\/2023\/02\/sub-arc-welding-equipment-4.jpg 800w, https:\/\/fractory.com\/wp-content\/uploads\/2023\/02\/sub-arc-welding-equipment-4-300x200.jpg 300w, https:\/\/fractory.com\/wp-content\/uploads\/2023\/02\/sub-arc-welding-equipment-4-768x512.jpg 768w\" sizes=\"(max-width: 800px) 100vw, 800px\" \/><\/p>\n<p>Submerged arc welding creates consistent welds by using a blanket of granulated flux. For this reason, <strong>the process can be operated only on positions that are flat and horizontal<\/strong>, with the weld advancing by either moving the welding system or the workpiece.<\/p>\n<p>Flux is fed into the joint manually or by using a flux hopper. A single electrode or multiple wire electrode system is placed into the working area, surrounded by the flux blanket. Parameters such as the welding current, arc voltage, and wire feed speed are set depending on the <a href=\"https:\/\/fractory.com\/types-of-metal\/\">type of metal<\/a>, its thickness, and desired <a href=\"https:\/\/fractory.com\/mechanical-properties-of-materials\/\">mechanical properties<\/a>. Electric current is supplied to the electrodes, producing intense heat that melts and fuses the base material and the filler wire to the bead.<\/p>\n<p>The molten metal cools down, creating strong uniform welds and reusable granular flux at the surface and slag underneath. A hopper collects the reusable flux, while slag is usually peeled off manually.<\/p>\n<p>SAW produces high-quality welds with fewer <a href=\"https:\/\/fractory.com\/welding-defects-types-causes-prevention\/\">weld defects<\/a> than other processes. However, this does not mean that defects won&#8217;t ever occur. When they do, it&#8217;s generally related to wrongly set welding parameters.<\/p>\n<h2>Flux<\/h2>\n<h3>Granular Flux<\/h3>\n<p>Granular flux inside a hopper is usually composed of oxides from aluminium, calcium, magnesium, manganese, silicon, titanium, and zirconium. This composition suits the type of electrode to achieve the metal&#8217;s desired properties as it chemically reacts as it melts.<\/p>\n<h3>Bonded Flux<\/h3>\n<p>Bonded flux is produced by drying the composition and slowly baking it, usually with a compound such as sodium silicate. As an advantage, bonded flux can contain alloying elements, offering flexibility for some applications and protection against rust.<\/p>\n<h3>Fused Flux<\/h3>\n<p>Fused flux is produced by melting the composition inside an electric furnace. The molten flux is formed into homogenous particles as it solidifies. It is excellent for creating consistent welds along the bead.<\/p>\n<h2>Wire Electrode<\/h2>\n<p>SAW uses a wire spool to feed the wire electrode into the weld. <strong>The wire&#8217;s thickness is usually between 1.6mm and 6mm<\/strong>. Electrodes may come in the form of solid, twisted, or cored wire and may be operated using different power sources.<\/p>\n<p>Specific circumstances may need the use of modified wire electrodes and electrode systems to achieve the desired weld profile:<\/p>\n<ul>\n<li>\n<p>Twin-wire<\/p>\n<\/li>\n<li>\n<p>Multiple wires<\/p>\n<\/li>\n<li>\n<p>Single wire with hot\/cold addition<\/p>\n<\/li>\n<li>\n<p>Metal powder additive<\/p>\n<\/li>\n<li>\n<p>Tubular wire<\/p>\n<\/li>\n<\/ul>\n<p>Multiple wire systems typically use a lead wire to improve penetration, while a trailing wire is used to add extra fill and improve the bead profile. Additional wires are used in the electrode system to add more deposition to the weld pool.<\/p>\n    <div class=\"shortcode-enhanced-cta\">\n        <div class=\"shortcode-enhanced-cta__content\">\n            <span class=\"v2-section-title v2-section-title--md\">Scale Your Manufacturing from Prototyping to Series<\/span>\n\n            <ul class=\"shortcode-enhanced-cta-list\">\n                                                            <li>\n                                                            <div class=\"shortcode-icon\">\n                                    <svg width=\"100%\" height=\"100%\" viewBox=\"0 0 33 32\" fill=\"none\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\">\n<path d=\"M16.4933 23.3059C21.7413 23.3059 25.9956 19.0515 25.9956 13.8036C25.9956 8.55559 21.7413 4.30127 16.4933 4.30127C11.2453 4.30127 6.991 8.55559 6.991 13.8036C6.991 19.0515 11.2453 23.3059 16.4933 23.3059Z\" stroke=\"currentColor\" stroke-width=\"2\" stroke-linecap=\"round\" stroke-linejoin=\"round\"\/>\n<path d=\"M1.16917 30.3724C1.35654 28.4452 2.49414 26.7455 4.20723 25.8488L11.5682 21.9542\" stroke=\"currentColor\" stroke-width=\"2\" stroke-linecap=\"round\" stroke-linejoin=\"round\"\/>\n<path d=\"M21.4318 21.9542L28.7928 25.8488C30.5058 26.7588 31.6434 28.4586 31.8308 30.3724\" stroke=\"currentColor\" stroke-width=\"2\" stroke-linecap=\"round\" stroke-linejoin=\"round\"\/>\n<path d=\"M12.8798 18.7956H6.10769C4.24738 18.7956 2.74843 17.2967 2.74843 15.4364V12.2243\" stroke=\"currentColor\" stroke-width=\"2\" stroke-linecap=\"round\" stroke-linejoin=\"round\"\/>\n<path d=\"M8.28921 9.02567H3.97971C3.29715 9.02567 2.74843 9.57439 2.74843 10.2569V14.2185C2.74843 14.901 3.29715 15.4498 3.97971 15.4498H7.13822\" stroke=\"currentColor\" stroke-width=\"2\" stroke-linecap=\"round\" stroke-linejoin=\"round\"\/>\n<path d=\"M24.7108 9.02567H28.7928C29.4753 9.02567 30.024 9.57439 30.024 10.2569V14.2185C30.024 14.901 29.4753 15.4498 28.7928 15.4498H25.8484\" 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<\/div>\n                            \n                                                            <span>Personal account manager<\/span>\n                                                    <\/li>\n                                                                                <li>\n                                                            <div class=\"shortcode-icon\">\n                                    <svg width=\"100%\" height=\"100%\" viewBox=\"0 0 33 34\" fill=\"none\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\">\n<path d=\"M17.5835 26.6203C16.8491 26.0906 15.4887 26.1628 14.959 25.4284C14.4293 24.694 14.9229 23.4299 14.6339 22.5631C14.345 21.6963 13.2133 20.986 13.2133 20.059C13.2133 19.1319 14.3691 18.3976 14.6339 17.5548C14.8988 16.7121 14.4293 15.4119 14.959 14.6895C15.4887 13.9672 16.8491 14.0274 17.5835 13.4976C18.3179 12.9679 18.655 11.6436 19.5218 11.3667C20.3886 11.0898 21.412 11.9566 22.351 11.9566C23.2901 11.9566 24.3375 11.1019 25.1802 11.3667C26.0229 11.6316 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stroke-linecap=\"round\" stroke-linejoin=\"round\"\/>\n<\/svg>\n                                <\/div>\n                            \n                                                            <span>Quality assurance<\/span>\n                                                    <\/li>\n                                                                                <li>\n                                                            <div class=\"shortcode-icon\">\n                                    <svg width=\"100%\" height=\"100%\" viewBox=\"0 0 35 27\" fill=\"none\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\">\n<path d=\"M17.576 22.1218H4.47786C3.039 22.1218 1.87455 20.7126 1.87455 18.9994V4.93701C1.87455 3.20888 3.039 1.81451 4.47786 1.81451H26.1796C27.6184 1.81451 28.7829 3.20888 28.7829 4.93701V9.53916\" stroke=\"currentColor\" stroke-width=\"2\" stroke-linecap=\"round\" stroke-linejoin=\"round\"\/>\n<path d=\"M1.87084 5.5081H28.7866\" stroke=\"currentColor\" stroke-width=\"2\" stroke-linecap=\"round\" stroke-linejoin=\"round\"\/>\n<path d=\"M1.87084 11.2636H18.0618\" stroke=\"currentColor\" stroke-width=\"2\" stroke-linecap=\"round\" stroke-linejoin=\"round\"\/>\n<path d=\"M6.22453 17.019H10.4299\" stroke=\"currentColor\" stroke-width=\"2\" stroke-linecap=\"round\" stroke-linejoin=\"round\"\/>\n<path d=\"M24.5182 25.63C29.2739 25.63 33.1292 21.7747 33.1292 17.019C33.1292 12.2633 29.2739 8.40808 24.5182 8.40808C19.7625 8.40808 15.9072 12.2633 15.9072 17.019C15.9072 21.7747 19.7625 25.63 24.5182 25.63Z\" stroke=\"currentColor\" stroke-width=\"2\" stroke-linecap=\"round\" stroke-linejoin=\"round\"\/>\n<path d=\"M24.5182 11.0967V17.019L27.7519 20.2528\" stroke=\"currentColor\" stroke-width=\"2\" stroke-linecap=\"round\" stroke-linejoin=\"round\"\/>\n<\/svg>\n                                <\/div>\n                            \n                                                            <span>Payment terms for companies<\/span>\n                                                    <\/li>\n                                                                                <li>\n                                                            <div class=\"shortcode-icon\">\n                                    <svg width=\"100%\" height=\"100%\" viewBox=\"0 0 31 33\" fill=\"none\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\">\n<g id=\"Layer_1\" clip-path=\"url(#clip0_874_1102)\">\n<path id=\"Vector\" d=\"M4.02589 18.9188H26.9832V26.7685C26.9832 27.6336 26.282 28.3257 25.426 28.3257H5.58309C4.71798 28.3257 4.02589 27.6245 4.02589 26.7685V18.9188Z\" stroke=\"currentColor\" stroke-width=\"2\" stroke-linecap=\"round\" stroke-linejoin=\"round\"\/>\n<path id=\"Vector_2\" d=\"M26.9832 18.9188H4.02589L6.52106 8.96545C6.67587 8.3371 7.24046 7.89999 7.88702 7.89999H23.1312C23.7777 7.89999 24.3423 8.3371 24.4972 8.96545L26.9923 18.9188H26.9832Z\" stroke=\"currentColor\" stroke-width=\"2\" stroke-linecap=\"round\" stroke-linejoin=\"round\"\/>\n<path id=\"Vector_3\" 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<span>On-time delivery by Fractory<\/span>\n                                                    <\/li>\n                                                                                    <\/ul>\n\n            <a class=\"c-button c-button--sm\" href=\"https:\/\/app.fractory.com\/quotes\/new\">Get a quote<\/a>\n        <\/div>\n\n        <div class=\"shortcode-enhanced-cta__media\">\n                            <video class=\"shortcode-video\" autoplay loop muted playsinline>\n                    <source src=\"https:\/\/fractory.com\/wp-content\/uploads\/2023\/01\/homepage-vid-v2.mp4\" type=\"video\/mp4\">\n                <\/video>\n                    <\/div>\n    <\/div>\n    \n<h2>Materials<\/h2>\n<p>Submerged arc welding process is used with the following materials:<\/p>\n<ul>\n<li>\n<p>Copper alloys<\/p>\n<\/li>\n<li>\n<p>Low to medium-carbon steels<\/p>\n<\/li>\n<li>\n<p>Low-alloy steels<\/p>\n<\/li>\n<li>\n<p>Mild steels<\/p>\n<\/li>\n<li>\n<p>Nickel-based alloys<\/p>\n<\/li>\n<li>\n<p><a href=\"https:\/\/fractory.com\/quenching-explained\/\">Quenched<\/a> and <a href=\"https:\/\/fractory.com\/tempering-explained\/\">tempered steel<\/a><\/p>\n<\/li>\n<li>\n<p>Stainless steels<\/p>\n<\/li>\n<li>\n<p>Uranium alloys<\/p>\n<\/li>\n<\/ul>\n<h2>Power Source<\/h2>\n<p>Submerged arc welding can operate on multiple power outputs, allowing it to manipulate the weld results. Multiple electrode systems enable SAW to run wires at different power sources, to better control the bead profile and penetration.<\/p>\n<p>DCEP offers the most stability and penetration, while DCEN is optimal in increasing deposition rates. Running this welding process in AC is the middle ground where a balance between the two is achieved.<\/p>\n<h2>Applications and Industries<\/h2>\n<div class=\"arve arve-hover-effect-darken\" data-mode=\"lazyload\" data-oembed=\"1\" data-provider=\"youtube\" id=\"arve-youtube-nrgzyk-h5oi\" style=\"max-width:900px;\" data-reset-after-played data-fullscreen=\"disabled\">\n<div class=\"arve-inner\">\n<div class=\"arve-embed arve-embed--has-aspect-ratio\" style=\"aspect-ratio: 500 \/ 281\">\n<span class=\"arve-ar\" style=\"padding-top:56.200000%\"><\/span><noscript class=\"arve-noscript\"><iframe credentialless referrerpolicy=\"strict-origin-when-cross-origin\" allow=\"accelerometer &#039;none&#039;;ambient-light-sensor &#039;none&#039;;autoplay;battery &#039;none&#039;;bluetooth &#039;none&#039;;browsing-topics &#039;none&#039;;camera &#039;none&#039;;ch-ua &#039;none&#039;;clipboard-read &#039;none&#039;;clipboard-write;display-capture &#039;none&#039;;document-domain 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data-src-no-ap=\"https:\/\/www.youtube.com\/embed\/NrGzYK-H5oI?feature=oembed&amp;iv_load_policy=3&amp;modestbranding=1&amp;rel=0&amp;autohide=1&amp;playsinline=0&amp;autoplay=0&amp;enablejsapi=1\" frameborder=\"0\" height=\"505.8\" name sandbox=\"allow-scripts allow-same-origin allow-presentation allow-popups allow-popups-to-escape-sandbox\" scrolling=\"no\" src=\"https:\/\/www.youtube.com\/embed\/NrGzYK-H5oI?feature=oembed&#038;iv_load_policy=3&#038;modestbranding=1&#038;rel=0&#038;autohide=1&#038;playsinline=0&#038;autoplay=1&#038;enablejsapi=1\" width=\"900\" title=\"Submerged Arc Welding\" loading=\"eager\"><\/iframe>\n<\/noscript><img decoding=\"async\" alt=\"Submerged Arc Welding\" src=\"https:\/\/i.ytimg.com\/vi_webp\/NrGzYK-H5oI\/hqdefault.webp\" srcset=\"https:\/\/i.ytimg.com\/vi_webp\/NrGzYK-H5oI\/mqdefault.webp 320w, https:\/\/i.ytimg.com\/vi_webp\/NrGzYK-H5oI\/hqdefault.webp 480w, https:\/\/i.ytimg.com\/vi_webp\/NrGzYK-H5oI\/sddefault.webp 640w, 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DOO\",\"duration\":\"59S\",\"description\":\"Welding pressure vessels with the submerged arc welding SAW process\"}<\/script>\n<\/div>\n\n<h3>Fabrication<\/h3>\n<p>SAW is one of the preferred welding processes in fabricating pressure vessels, pipes, and boilers due to its strength in longitudinal and circumferential welding. This welding operation achieves a smooth weld pool from the continuously fed electrode.<\/p>\n<h3>Shipbuilding<\/h3>\n<p>The flexibility of SAW process allows it to be performed both indoors and outdoors which makes it suitable for shipbuilding. It&#8217;s perfect for creating long, straight welds for heavy metals which make up ship parts.<\/p>\n<h3>Automotive<\/h3>\n<p>Metals used in the automotive and military industry are fit for SAW, along with the speed and efficiency it brings. This welding method is also perfect for automation, with the option to have multiple or single-pass welds based on the metal&#8217;s thickness.<\/p>\n<h3>Railways<\/h3>\n<p>The submerged arc process allows deep weld penetration, which is attractive to the railway industry.<\/p>\n<h2>Advantages of SAW<\/h2>\n<ol>\n<li>\n<p>The blanket of granular flux creates minimal welding fume and spatter.<\/p>\n<\/li>\n<li>\n<p>Allows performing semiautomatic or fully automatic welding.<\/p>\n<\/li>\n<li>\n<p>Flexible for both indoor and outdoor applications.<\/p>\n<\/li>\n<li>\n<p>Creates smooth, uniform and deep welds.<\/p>\n<\/li>\n<li>\n<p>Around 50-90% of the flux is reusable and recyclable.<\/p>\n<\/li>\n<\/ol>\n<h2>Limitations of SAW<\/h2>\n<ol>\n<li>\n<p>Limited to flat and horizontal welding positions<\/p>\n<\/li>\n<li>\n<p>A rather narrow range of weldable metals.<\/p>\n<\/li>\n<li>\n<p>Requires post-welding slag removal.<\/p>\n<\/li>\n<li>\n<p>Practically restricted to circumferential and long straight beads.<\/p>\n<\/li>\n<li>\n<p>Precise parameters are required to achieve desired weld deposit since welds aren&#8217;t visible while welding.<\/p>\n<\/li>\n<\/ol>\n","protected":false},"excerpt":{"rendered":"<p>Submerged arc welding is a standard industrial process wherein an arc is formed between a workpiece and an electrode. It was invented in 1935 by the E. O. Paton Electric [&hellip;]<\/p>\n","protected":false},"author":29,"featured_media":20811,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[6490,6526],"tags":[],"yst_prominent_words":[673,2492,5310,5395],"class_list":["post-20809","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-fabrication-methods","category-welding"],"acf":[],"_links":{"self":[{"href":"https:\/\/fractory.com\/wp-json\/wp\/v2\/posts\/20809","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/fractory.com\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/fractory.com\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/fractory.com\/wp-json\/wp\/v2\/users\/29"}],"replies":[{"embeddable":true,"href":"https:\/\/fractory.com\/wp-json\/wp\/v2\/comments?post=20809"}],"version-history":[{"count":6,"href":"https:\/\/fractory.com\/wp-json\/wp\/v2\/posts\/20809\/revisions"}],"predecessor-version":[{"id":23823,"href":"https:\/\/fractory.com\/wp-json\/wp\/v2\/posts\/20809\/revisions\/23823"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/fractory.com\/wp-json\/wp\/v2\/media\/20811"}],"wp:attachment":[{"href":"https:\/\/fractory.com\/wp-json\/wp\/v2\/media?parent=20809"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/fractory.com\/wp-json\/wp\/v2\/categories?post=20809"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/fractory.com\/wp-json\/wp\/v2\/tags?post=20809"},{"taxonomy":"yst_prominent_words","embeddable":true,"href":"https:\/\/fractory.com\/wp-json\/wp\/v2\/yst_prominent_words?post=20809"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}