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One Side Welding Submerged Arc Welding Process

One Side Welding Submerged Arc Welding Process

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One Side Welding Submerged Arc Welding Process

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  1. One Side Welding Submerged Arc Welding Process Welding in Shipbuilding Conference May 10-11, 2011 by Sean P Moran

  2. Outline of Presentation • Introduction of the Process • Procedure for Application • Weld Evaluation Results • Supporting Discussion • Summary

  3. Introduction 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

  4. Advantages, 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

  5. Limitations, SAW-OSW • Limited Fit Up Robustness • Fixture and Clamping • Flux Bed Mechanism and Procedure • Multiple Weld Head Requirements

  6. Procedure 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

  7. Weld 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

  8. Equipment Selection • PEH Controls • LAF 1000 DC • TAF 800 AC • A6 Wire feeders • Knurled Feed Rolls for (Tubular Wire)

  9. Equipment Set Up • Electrode angle 90º Lead 65º Trail • 3/4" Distance between electrodes

  10. Welding 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

  11. Application 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

  12. Welding Parameters

  13. Weld Evaluation Results

  14. Macro-Sections - No Gap

  15. Macro-Sections – 1/16 Gap

  16. Macro-Sections - 3/32 Gap

  17. Supporting 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

  18. Future Work • Varying Gap Width of 0 - .5T • Increase and Alter Electrode Diameters • Robust .5T Full Length Gap • Evaluate Mechanical Weld Properties

  19. Summary • 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