Arc Welding

Nauman Ahmad
SEN-EE Lecturer
UMT Lahore
 Flux Shielded/Fusion Arc Welding
Manual/Shielded Metallic Arc
Welding (MMAW)
Submerged Arc Welding (SAW)

MMAW: a manual process of

welding used for joining shapes
that cannot be easily set up for
automatic welding methods

• The arc is struck by short

circuiting the electrode with the
work piece.

• Welding current is chosen

according to the electrode
diameter, type of electrode, and
the kind of welding job.

• The arc voltage is determined as

the function of arc length
 MMAW
• The electrodes are thoroughly dried or baked
after production, because moisture will cause an
unstable arc and porosity in the weld metal.
• The coating of the electrode burns off faster than
the coating flux that forms a crucible and this
makes the arc heat to be focussed at the welding
point.
• Flux removes the impurities from the molten
metal. The gaseous envelope, formed by the
decomposition of the ingredients of flux, protects
the molten weld pool from atmospheric contact.
 MMAW
• Power sources of constant current type are
used with drooping characteristics. Power
sources of constant voltage type are not
suitable.
• Heat developed by the arc is:
W (joules) = V (volt) * A (amps) * t (sec)
• If the arc is travelling at a speed of S
mm/minute, the heat input rate (HIR) of the
arc will be:
HIR = V * A * 60/S, Joules/mm length of the joint
 Power Sources for MMAW
• AC or DC power source can be successfully used. DC
can be used with all types of electrodes.
• In DC:
– Starting of welding process and maintain a shorter arc is
easy.
– With the straight polarity, i.e, electrode negative:
• The arc heat is concentrated on the electrode and consequently
melting and deposition rates are higher, welding is more rapid and
the worked piece is less susceptible to distortion.
• For sheet metal welding, the burn-through problems are
minimized because of shallow penetration.
– Reverse polarity (electrode positive) is used for most non-
ferrous metals and with basic low hydrogen electrodes.
 Power Sources for MMAW
• DC Disadvantages:
– Problems of arc blow occur when welding ends of
joints, corners etc.
• AC does not present such problems.
 Submerged Arc Welding
• The heat required to fuse the
metal is generated by an
electric current passing
through between the welding
wire and the work piece.

• The tip of the welding wire,

the arc and the weld area are
covered by a layer of granular
flux which completely shields
the welding zone from
atmospheric contact.

• SAW has slower cooling and

solidification characteristics
and can be used for welding of
materials in higher gauges.
 Submerged Arc Welding
• SAW power source should be capable of
supplying heavy current at 100% duty cycle.
• DC power source:
– Gives easy and accurate arc start.
– Control of bead shape is best with electrode positive,
while high deposition rate is achieved with electrode
negative, though the penetration will be shallow.
– Good weld speed and good manoeuverability to weld
different contours at high weld speed.
• AC is generally preferred for larger diameter (>
4mm) wires.
 Submerged Arc Welding
• The process variables are:
– Welding current and voltage.
– Welding speed and electrode stick out.
– Width and depth of flux.
– Joint design.
a) Welding current and voltage:
too high a current will produce a digging arc, highly narrow weld seam and a
large HAZ (Heat Affected Zone).
too low a current will produce an unstable arc,
so we follow some standards to use an optimum range of current for different
wire diameters
High welding voltage will produce a wider and less deeply penetrated weld.
Low arc voltage may improve the penetration in a deep groove joint but slag
removal will be difficult in such cases.
b) Welding speed and electrode stick out:
High speed will result in under cuts, porosity and uneven bead shapes
Too low a speed will produce heavy reinforcements and slag inclusions
 Submerged Arc Welding
Electrode stick out: is the length of the wire
extending beyond the tip of the contact tube
above the work piece.
Too high a stick out will soften the wire due to
heating and, hence, stiffness of the wire will
be lost. Energy supplied to the arc will be
reduced, resulting in lower arc voltage and
different bead shape. The depth of the
penetration will also be decreased.
 Submerged Arc Welding
• Advantages: high weld metal quality and
smooth and uniform weld finish. Smoke and
arc flash are absent in SAW. The operator’s
skill is minimum in SAW and it is extensively
used in heavy steel plate fabrications.