One Side Welding Submerged Arc Welding Process

One Side Welding Submerged Arc Welding Process

Welding in Shipbuilding Conference

May 10-11, 2011

by Sean P Moran

Outline of PresentationOutline of Presentation

Introduction of the Process

Procedure for Application

Weld Evaluation Results

Supporting Discussion

Summary

Introduction of the ProcessIntroduction of the Process

Submerged Arc Welding (SAW) Application

Multiple Wire Tandem Procedure

Single (One) Side Full Penetration Welds

Weld Travel Speeds Capable of 60 IPM

Advantages, SAW-OSWAdvantages, SAW-OSW

Reduce Production Time

Eliminate the Additional Cost of Equipment Needed to Rotate the Plates for Two-Sided Welds

Capable of Achieving Full-Penetration Square Butt Seams in ¼” Plate From One Side

Excellent Welder Appeal – Ease of Use

Limitations, SAW-OSWLimitations, SAW-OSW

Limited Fit Up Robustness

Fixture and Clamping

Flux Bed Mechanism and Procedure

Multiple Weld Head Requirements

Procedure for ApplicationProcedure for Application

Tandem Welding Process using DC Lead and AC Trail

Solid Wire Lead using Solid and Tubular Wire Trail

Square Butt Joint Preparation with 0 – 1/8 Gaps

Non-Floating 1½” Width and 9/32” Depth Flux Bed

Copper Chill Bar with 1½” x 1/16” Center Recess

Weld Joint Fit UpWeld Joint Fit Up

Two ¼” x 2” x 18” hot rolled plates with ¼” x 2” x 9 run off tabs at either end

Set two 18” bars side by side, set the gap, weld tabs and 3 tack welds at ¼, ½ & ¾ of plate length

Equipment SelectionEquipment Selection

PEH Controls

LAF 1000 DC

TAF 800 AC

A6 Wire feeders

Knurled Feed Rolls for (Tubular Wire)

Equipment Set UpEquipment Set Up

Electrode angle 90º Lead 65º Trail 3/4" Distance between electrodes

Welding ConsumablesWelding Consumables

DC/AC - 1/8” Spoolarc 81 Solid Wire EM12K

DC/AC - 1/8” Alloy Shield 70S Tubular Wire EC1-H8

Welding Flux: OK Flux 10.71 F7A5

Backing Flux: OK Flux 10.69 No AWS Classification

Application Set UpApplication Set Up

2½” x 1½” x 6’ copper chill with 1½” x 1/16” center recess OK Flux 10.69 applied over the top of the chill Excess flux screen off forming a 7/32” crown

Welding ParametersWelding Parameters

Spoolarc 81 Solid Wire Lead and Trail

Gap DC Lead AC Trail Travel

Inch Amps Volts Amps Volts IPM

0 700 29 550 34 58

1/16 700 29 600 35 58

3/32 425 29 600 32 50

1/8 N/A

Spoolarc 81 Solid Wire Lead and Alloy Shield 70S Trail0 700 29 550 34 58

1/16 700 29 600 35 58

3/32 425 29 600 32 50

1/8 N/A

Weld Evaluation ResultsWeld Evaluation Results

Spoolarc 81 Solid Wire Lead and Trail

Gap Width

Travel Speed Results

0” 58 IPM Top - easy peeling - straight edges

  Bottom - medium bead, good edges, easy peeling

1/16” 58 IPM Top - easy peeling medium reinforcement

  Bottom - medium bead, easy peeling

3/32” 50 IPM Top - almost flat - self peeling

Bottom - medium bead - slightly uneven

Spoolarc 81 Solid Wire Lead and Alloy Shield 70S Trail0” 58 IPM Top – self peeling - medium reinforcement - smooth

  Bottom - medium bead- smooth - self peeling

1/16” 58 IPM Top - self peeling - medium reinforcement - smooth

  Bottom - medium bead- smooth - self peeling

3/32” 50 IPM Top - smooth medium reinforcement - self peeling

Bottom - medium bead- slightly uneven - self peeling

Macro-Sections - No GapMacro-Sections - No Gap

Macro-Sections – 1/16 GapMacro-Sections – 1/16 Gap

Macro-Sections - 3/32 GapMacro-Sections - 3/32 Gap

Supporting DiscussionSupporting Discussion

Travel Speeds Approaching 60 IPM

Excellent Full Penetration Profiles

Increase Face Reinforcement with Tubular Wire

Gap Size of 1/8” Prove to Have Limited Robustness

Future WorkFuture Work

Varying Gap Width of 0 - .5T

Increase and Alter Electrode Diameters

Robust .5T Full Length Gap

Evaluate Mechanical Weld Properties

SummarySummary

One Sides Full Penetration SAW

Tandem with Either Solid or Tubular Trail

Robust Gap Widths of 3/32 inch

Weld Travels Speeds Approaching 60 IPM

User Friendly - Ease of Operator Use