Welding Processes 29

Constant potential power source with 750-1000 amps at 100 per cent duty and
with a open circuit voltage of 60 V minimum is used. The electrode could be solid
or flux-cored fed at a rate of 20-150 mm/second.
The quality of weld in ESW depends on (a) the ratio of width of the weld pool
and its maximum depth, known as Form Factor, (b) weld current and voltage, (c)
electrode extension and oscillation, (d) slag depth, (e) number of electrodes and
their spacing etc. The weld will be more crack-resistant if the form factor is high.
Weld voltage controls the depth of fusion. Increasing voltage increases the depth
of fusion and the width of the weld. Increasing welding current will increase the
deposition rate and also the depth of molten weld pool. However, too high a current
may result in deposits which will be crackprone.
Oscillation of electrode will ensure proper heat distribution and fusion. The
slag bath depth should be sufficiently deep so that the wire enters into it and melts
beneath the surface. With shallow bath the slag will split and arcing will occur at
the surface. For best results the bath depth should be around 40 mm.
The electrode can be solid and metal-cored. AWS 5.25-1978 gives the
specifications of flux wire combination for ESW of carbon and high strength low
alloy steels. In ESW, the dilution is to the extent of 30 - 50 per cent by the base
metal. Hence care should be taken to select the proper wire for a particular steel.
Many of the solid electrodes are the same as with SAW and MIG/CO2 welding.
The flux used must be conductive and must have proper viscosity to permit a
good stirring action in the flux pool. The flux must have a melting range lower
than that of the weld metal and metallurgically compatible with the alloy being
welded. A basic flux is usually employed for carbon steel, low alloy steel and
stainless steel. Fluxes are classified on the basis of the mechanical properties of a
weld deposit made with a particular electrode.
Plates and other heavy sections upto 450 mm are commonly welded by electro-
slag process. Heavy pressure vessels for chemical, petrochemical and power
generating industries are usually welded by ES process only.
In ESW, the weld metal stays molten for a long time and permits slag-refining
action, namely, escape of dissolved gases and transfer of non-metallic inclusions
to the slag-bath. The prolonged high temperature and the slow cooling rate in
ESW result in a wide coarse grained HAZ having relatively soft high temperature
transformation products. The weld itself will have columnar cast structure. As
such the toughness of the weld and HAZ will not be very high and if the service
condition does not require high toughness the weld as such can be made use of.
However, if the service condition requires high toughness of the weld, then proper
normalising heat treatment must be carried out, so that all traces of cast structure
are removed and toughness properties are improved.
1.2.3.3 Induction pressure welding
This is a solid phase welding, obtained by the use of high frequency induction
heating and by simultaneous application of pressure. Oxidation is avoided by
purging with hydrogen gas. The surfaces to be joined are heated by induction
current at 4kc/sec, produced by an inductor in series with two capacitors, powered
by a transformer with two high frequency alternators. A typical seam welding of a