EXPERIMENT: 1

Aim
To study submerged arc welding process.

Apparatus
Submerged Arc Welding Machine
Power Source (CPRA 800(S))

THEORY
Submerged arc welding (SAW) process uses heat generated by an electric arc established
between a bare consumable electrode wire and the work piece. Since in this process,
welding arc and the weld pool are completely submerged under cover of granular fusible
and molten flux therefore it is called so. During welding, granular flux is melted using heat
generated by arc and forms cover of molten flux layer which in turn avoids spatter
tendency and prevents accessibility of
atmospheric gases to the arc zone and
the weld pool. The molten flux react
with the impurities in the molten weld
metal to form slag which floats over
the surface of the weld metal. Layer of
slag over the molten weld metal
results:

Increased protection of weld

metal from atmospheric gas
contamination and so improved
properties of weld joint
Reduced cooling rate of weld metal and HAZ owing to shielding of the weld pool by
molten flux and solidified slag in turn leads to a) smoother weld bead and b) reduced the
cracking tendency of hardenable steel.
Features: -
Welding Head: -
It feeds filler material to the welding joint. Electrode gets energized here.

Flux: -
The granulated flux shields and thus protects molten weld from atmospheric
contamination. The flux cleans weld metal and can also modify its chemical composition.
The flux is granulated to a definite size. It may be of fused, bonded or mechanically mixed
type. Flux used was granular and of fused type.

Electrode: -
SAW filler material usually is a standard wire as well as other special forms. This wire
normally has a thickness of 1.6 mm to 6 mm (1/16 in. to 1/4 in.). The electrode
composition depends upon the material being welded. Alloying elements may be added
in the electrodes. Electrodes are available to weld mild steels, high carbon steels, low and
special alloy steels, stainless steel and some of the nonferrous of copper and nickel.
Electrodes are generally copper coated to prevent rusting and to increase their electrical
conductivity. Electrodes are available in straight lengths and coils.

Welding Operation: -
The flux starts depositing on the joint to be welded. Since the flux when cold is non-
conductor of electricity, the arc may be struck either by touching the electrode with the
work piece or by placing steel wool between electrode and job before switching on the
welding current. In all cases the arc is struck under a cover of flux. Flux otherwise is an
insulator but once it melts due to heat of the arc, it becomes highly conductive and hence
the current flow is maintained between the electrode and the workpiece through the
molten flux. The upper portion of the flux, in contact with atmosphere, which is visible
remains granular (unchanged) and can be reused. The lower, melted flux becomes slag,
which is waste material and must be removed after welding.
The electrode at a predetermined speed is continuously fed to the joint to be welded. In
automatic welding a separate drive moves either the welding head over the stationary
job or the job moves/rotates under the stationary welding head. The arc length is kept
constant by using the principle of a self-adjusting arc. A backing plate of steel or copper
may be used to control penetration and to support large amounts of molten metal
associated with the process.
Process Variables: -

Welding Current
Welding current is the most influential process parameter for SAW because it determines
the melting rate of electrode, penetration depth and weld bead geometry. However, too
high current may lead to burn through owing to deep penetration, excessive
reinforcement, increased residual stresses and high heat input related problems like weld
distortion. On the other hand, selection of very low current is known to cause lack of
penetration & lack of fusion and unstable arc. Selection of welding current is primarily
determined by thickness of plates to be welded and accordingly electrode of proper
diameter is selected.

Electrode Diameter (mm) Welding Current (A)

1.6 150-300

2.0 200-400

2.5 250-600

3.15 300-700

4.0 400-800

6.0 700-1200

Welding Voltage
Welding voltage has marginal effect on the melting rate of the electrode. Welding voltage
commonly used in SAW ranges from 20-35 V. Selection of too high welding voltage (more
arc length) leads to flatter and wider weld bead, higher flux consumption, and increased
gap bridging capability under poor fit-up conditions while low welding voltage produces
narrow & peaked bead and poor slag detachability.
Welding speed
Required bead geometry and penetration in a weld joint are obtained only with an
optimum speed of welding arc during SAW. Selection of a speed higher than optimum
one reduces heat input per unit length which in turn results in low deposition rate of weld
metal, decreased weld reinforcement and shallow penetration. Further, too high welding
speed increases tendency for
Undercut in weld owing to reduced heat input,
Arc blow due to higher relative movement of arc with respect to ambient gases and
Porosity as air pocket are entrapped due to rapid solidification of the weld metal.
On other hand low welding speed increases heat input per unit length which in turn may
lead to increased tendency of melt through and reduction in tendency for development
of porosity and slag inclusion. Bead geometry and depth of penetration are two important
characteristics of the weld bead that are influenced by size of the electrode for a given
welding current setting.
Advantages
High deposition rates (over 45 kg/h (100 lb/h) have been reported).
High operating factors in mechanized applications.
Deep weld penetration.
Sound welds are readily made (with good process design and control).
High speed welding of thin sheet steels up to 5 m/min (16 ft/min) is possible.
Minimal welding fume or arc light is emitted.
Practically no edge preparation is necessary depending on joint configuration and
required penetration.
The process is suitable for both indoor and outdoor works.
Welds produced are sound, uniform, ductile, and corrosion resistant and have good
Impact Value.

Single pass welds can be made in thick plates with normal equipment.
The arc is always covered under a blanket of flux, thus there is no chance of spatter
of weld.

50% to 90% of the flux is recoverable, recycled and reused.

Limitations
Limited to ferrous (steel or stainless steels) and some nickel-based alloys.
Normally limited to the 1F, 1G, and 2F positions.
Normally limited to long straight seams or rotated pipes or vessels.
Requires relatively troublesome flux handling systems.
Flux and slag residue can present a health and safety concern.
Requires inter-pass and post weld slag removal.
Requires backing strips for proper root penetration.
Limited to high thickness materials.
Observations
Submerged arc welding was studied thoroughly by performing bead formation on a mild
steel workpiece at the following settings.
Voltage Trolley speed Wire feed rate
28 V 30 cm/min 6 cm/min

Result
Mild steel bar was welded on the machine and a bead along the length was obtained
having the following characteristics:

Plate Weight Time Wire Consumed Current

1.30 kg 38.7 s 18 inches 265A

Precautions
1. Clean the plate before welding.
2. Be careful while handling hot welded plate.
3. Mark the reading carefully on wire.
 EXPERIMENT: 2
Aim: To cut the welded workpiece from Power hacksaw in two pieces of
2x1 inches size.

Apparatus:
A welded workpiece
Power Hacksaw machine
Abrasive cut off machine
Ruler
Chalk etc.

Theory:
1. Power Hacksaw: Power hacksaw is used to cut the large size(section) of
metal such as mild steel plate of thickness 10-15mm, which is very hard
work with a normal hand hacksaw. Therefore, power hacksaw has been
developed to carry out the difficult and time-consuming work. The heavy
arm moves backward and forward, cutting on the backward stroke. power
hacksaw has an electric motor that power the blade through pully system.
Some have ratchet system.
2. Abrasive Cut-off Machine: Abrasive(Al2O3,SiC) Cutoff machine is a
power tool which is typically used to cut head materials and that of
quick thick workpiece. The cutting action is performed by an abrasive
disk, similar to grinding wheel. The cutting wheel and motor are
mounted a pivoting arm attached to a fixed base plate.
Abrasive saws typically use composite friction disc blades to abrasively
cut through the steel.
Result: -
Two pieces of 2x1inch workpiece were cut out.
 EXPERIMENT: 3
Aim: To perform finishing of welded workpiece cut out pieces from the
sides for further analysis.
Apparatus:

Belt linishing machine

Welded workpiece
Theory:

Belt linishing machine: It is used to perform abrasive machining

process on metal and other materials. It is typically used for finishing
process in the industry. Four belts, coated with abrasive material is
run over the surface to be processed in order to remove the material
or produce the desired product(finish).
to achieve desired material removal, it is important to look into the
variable that affect it. These include the work material properties, the
type of abrasive grinding belt, belt speed, belt sequence, type of
lubricant and grinding process.

Belt linishing machine

 Rotary grinder machine: -Rotary surface grinding is a highly
productive process due to the large amount of grinding wheel
in contact with the surface area of the workpiece. For each
rotation of the rotary table the entire surface to be ground
comes in contact with the grinding wheel surface. Many
applications may require custom options or electromagnetic,
mechanical, vacuum, pneumatic or hydraulic work-
holding. Our design team specializes in collaboration with your
manufacturing or engineering group to produce work-holding
devices to meet your process needs of repeatable quality,
accuracy and productivity.
Variable speed rotary tables are standard with variable force
electromagnetic chuck and electronic sensed
damage. Through spindle vacuum, pneumatic or hydraulic are
configuration features on most rotary surface grinders.
Result: -

The finishing operation was performed successfully.

After finishing Before finishing

 EXPERIMENT: 4
Aim: To determine the depth of penetration, area of penetration,
height of reinforcement, area of reinforcement, width of bead and area
of Heat Affected Zone(HAZ).

Apparatus:
Nitral solution
Polishing machine
Welded workpiece

Theory:
Polishing:
Polishing is a finishing process for smoothening a workpiece
surface using an abrasive disc polisher.
Polisher is used to enhance the appreance of an item, reduce
surface roughness, remove oxidation and create reflective
surface.

Etching:
Etching of the weld allows the tester to see a cross-section of the
weld. It can also show up deflects such as porosity, inclusions and
poor fusion. To perform this test, an acid solution is applied with a
soft clean cloth, wiping over the test piece. The acid used is nitric
acid (10%) dissolved in distilled water (90%).
Nitric acid is used because of its rapid oxidising properties.
Calculations:
Weld Dilution: Ap/(Ap+Ar) = 32.215/66.365

=0.485

Weld Penetration Safe Factor(WPSF): Bead width/Hp

= 14.110/3.642
= 3.87
Weld Reinforcement Form Factor(WRFF): Bead width/Hr
= 14.110/3.468
= 4.0

Result: -
Height of reinforcement(Hr) = 3.468mm
Depth of penetration(Hp) = 3.642mm
Width of weld bead(W) = 14.110mm
Area of penetration = 32.215mm2

Area of reinforcement = 34.150mm2

Area of Heat Affected Zone(HAZ) = 49.118mm2