Welding Processes 13

Table 1.3 Optimum range of current for different wire diameter

Wire diameter (mm) Current range (amps)

1.6 150 – 400
2.0 200 – 500
2.4 250 – 600
3.2 300 – 800
4.0 450 – 1000
5.0 600 – 1300
6.3 700 – 1400

High welding voltage will produce a wider, flatter, less deeply penetrated weld.
A wider bead will increase the flux consumption. Low arc voltage will produce a
stiffer arc and may improve the penetration in a deep groove joint. However, slag
removal will be difficult in such cases.
The welding travel speed influences the weld size and penetration. High speed
will result in undercuts, arc blow, porosity and uneven bead shapes. The bead
shape is essentially controlled by the welding speed. Too low a speed will produce
heavy reinforcement and cause slag inclusions.
Electrode stick out is the length of the wire extending beyond the tip of the
contact tube above the work piece. Higher stick out will increase the deposition
rate. However, too high a stick out will soften the wire due to heating and hence
stiffness of the wire will be lost. Increased electrode stick out reduces the energy
supplied to the arc, resulting in lower arc voltage and different bead shape. The
depth of penetration is also decreased. Maximum electrode stick outs recommended
are
75 mm for 2.0, 2.4 and 3.2 mm wire dia.
125 mm for 4.0, 4.8 and 5.6 mm wire dia.
The heat input rate (HIR) affects the microstructure of the weld metal and HAZ.
The higher the heat input rate, the lower is the cooling rate of the weld and the
HAZ of the parent metal. Weld and HAZ microstructure and toughness will be
dependent on the HIR.
U and V weld joints can be used in SAW. Because of the high current used in
SAW, a backing is always necessary for this process. The backing may be provided
by means of flux, backing strip, or through the weld metal itself deposited by
MMA process. The common defects encountered in SAW are slag inclusions,
porosity and cracking of welds. The process variables mentioned may introduce
these defects, if not properly adjusted to suit the welding condition.
Submerged arc welding is considered as an excellent and efficient process to
use on nearly all ferrous metal welds of exceptionally good quality. Carbon, alloy
and stainless steels upto 12 mm thick can be safely welded in single pass, while
thicker cross section requires multi-pass welding. Though the arc speed and the
metal deposition rates are superior to other welding processes, the only limitation
is the positional welding. Because a granular flux must be used to shield the weld
metal, in practice, only flat position welding is done or inclination upto 15° from
flat can be used.