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Parametric Effect on Mechanical

Properties in Submerged arc welding

process - A review

RAVINDER PAL SINGH*

Industrial and Production Engg. Deptt.

Dr.B.R.Ambedkar National Institute of Technology

Jalandhar (Punjab)-144011(INDIA)

Mobile No. +91- 09417434200

Email: rps_syal@rediffmail.com

R.K.GARG

Industrial and Production Engg. Deptt.

Dr.B.R.Ambedkar National Institute of Technology

Jalandhar (Punjab)-144011(INDIA)

D.K.SHUKLA

Mechanical Engg. Deptt.

Dr.B.R.Ambedkar National Institute of Technology

Jalandhar (Punjab)-144011(INDIA)

Abstract

Submerged arc welding is a mechanized, high deposition rate welding process which can produce a smooth bead with deep penetration at a faster travel speed. Welding input parameters play a very significant role in determining the quality of a weld joint. The joint quality can be assessed in terms of weld bead geometry, mechanical properties and distortion. Higher quality and cost effective welds can be achieved by understanding the weld metal properties and the influence of welding parameters. A comprehensive review of parameters of submerged arc welding and their effect on weld quality have been reported in this paper.

Keywords: Submerged arc welding, parametric effect, weld bead geometry, heat affected zone Corresponding author: rps_syal@rediffmail.com

Contents

1. Introduction

2. SAW process

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2.1.1. Arc voltage

2.1.2. Welding wire extension

2.1.3. Travel speed

2.1.4. Wire feed rate

2.1.5. Filler wire diameter

2.1.6. Flux

2.1.7. Polarity

3. Review of the quality of weld

3.1. Parametric effect on weld bead geometry

3.2. Parametric effect on mechanical properties

3.3. Parametric effect on heat affected zone

4. Discussion

1. Introduction

Welding is an efficient and economical method for joining of metals. Welding has made significant impact on the large number of industries by raising their operational efficiency, productivity and service life of the plant and relevant equipment [1]. Welding is one of the most common fabrication techniques which is extensively used to obtain good quality weld joints for various structural components. The present trend in the fabrication industries is to automate welding processes to obtain high production rate. Welding processes can be automated by establishing the relationship between the process parameters and weld bead geometry to predict and control the weld bead quality [2]. These relationships can be developed by using of experimental design techniques [3]. Submerged arc welding is preferred over other methods of welding because of its high reliability, deep penetration, and smooth finishing and high productivity [4]. Due to high deposition rate, excellent surface appearance, invisible arc and lower welder skill requirement submerged arc welding process is widely used in fabrication of pressure vessel, marine vessel, pipelines and offshore structures [5]. It has also been revealed that slag produced in the process can be reused [6]. So, these qualities have made this welding process as a preferred choice in industries for fabrication.

2. Submerged Arc Welding Process

Submerged arc welding (SAW) is a mechanized and high deposition rate welding process. It is a fusion welding process in which heat is produced by maintaining an arc between the work and continuously fed filler wire electrode. Figure1 shows schematic diagram of submerged arc welding. Submerged arc welding process as shown in figure 2 employs a continuous bare electrode wire in solid form and a blanket of powdered flux. The flux mount is of sufficient depth to submerge completely the arc column so that there is no spatter or smoke and the weld is shielded from the atmospheric gases. Flux physically influences the weld metal as it affects weld bead geometry and load carrying capability [7, 8]. It also affects chemistry of the weld metal by altering its mechanical properties [9, 10] and microstructure of the weld metal [11, 12]. The heat produced by the arc is used to melt the work piece. Hence a high quality weld of desired composition is obtained by above process without the application of pressure.

2.1. Submerged Arc Welding Process Parameters

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Figure 1: Schematic arrangement of submerged arc welding

2.1.1 Arc Voltage

The arc voltage controls the arc length, flux consumption and weld metal properties. Increase in arc voltage increases the arc length which results in wider bead width [14]. As increasing the arc voltage increases the arc length so more heat is available to melt the metal and flux due to which more alloying elements enter the weld metal. Thus arc voltage affects the weld metal composition. Flux consumption is also increased as more flux is melted. Murugun et al. [15] observed that voltage has no significant effect on penetration, reinforcement decreases but bead width increases with increases in voltage. Figure 3 shows that for a particular electrode diameter and extension irrespective of the electrode positive or negative polarity there is increases in bead width with increase in voltage [16].

2.1.2 Welding Wire Extension (Stickout)

Short welding wire extension results in deeper penetration due to low resistive heating (I2R), while long extension results in shallow penetration due to high resistive heating. Higher resistive heating due to long extension however results in increase in welding wire temperature and metal deposition rate. Chandel et al.[5] also reported thatlonger electrode extension can be used to increase the melting rate. Datta et al. [17] revealed that Increase in stickout increases hardness, decreases impact strength and yield strength whereas initial decreases but thereafter an increase has been observed in ultimate tensile strength of the weldments (Figure 4.a-d).

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Figure 3: Effect of arc voltage on bead width (after Yang et al. [16])

22 23 24 25 26

362 367 372 377 Stickout Ha rd n e s s 26 25 24 23 22 15.2 15.1 15.0 14.9 14.8 14.7 14.6 Stickout Im pac t S tr eng th

Figure 4.a: Effect of stickout on hardness (after Datta et al.[17])

Figure 4.b: Effect of stickout on impact strength (after Datta et al.[17])

 

22 23 24 25 26

342 343 344 345 346 Stickout Y iel d s tr engt h

Figure 4.c: Effect of stickout on yield strength

(after Datta et al. [17])

26 25 24 23 22 440 435 430 425 Stickout U lti m a te t e n s ile s tr e n g th

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2.1.3 Travel Speed

Welding speed or travel speed controls depth of penetration. Increase in welding speed decreases the width of weld, however slower welding speed increases depth of penetration as compared to faster welding speed because in the former condition the layer of molten metal is reduced which leads to higher current conduction towards bottom of plate [18]. Murugun et al. [19] also found that penetration and width decreases with increase in travel speed but reinforcement decreases to optimum value with increase in travel speed. It is clear from figure 5 that with the increase in welding speed the bead width increases initially but it decreases with further increase in the welding speed.

2.1.4 Wire Feed Rate

The wire feed rate is the most influential control of fusion and penetration. Increasing the wire feed rate increases the welding current so the deposition rate and penetration increase, reinforcement height increases marginally whereas bead width decreases [20]. It is further revealed that wire feed rate is the most significant factor which affects the dilution [21]. Murugun et al. [19] found that penetration, reinforcement and dilution and HAZ increase with increase in wire feed rate. Figure 6 indicate that HAZ has an increasing trend with increase in the wire feed rate. This is due to reason that with the increase in wire feed rate, arc current increases which further increases the heat input and hence area of heat affected zone also increases.

2.1.5 Filler Wire Diameter

Changing the electrode diameter in submerged arc welding will change the current density for given current. Miller [22] reported that at a given current setting, a small wire diameter electrode gives a higher current density and thus a higher deposition rate than a larger wire diameter electrode. Tuesk [23] also found that melting rate decreases with the increase in filler wire diameter which is shown in figure 7. It is further revealed that for the same current intensity electrode melting rate using 3 mm wire diameter is 30-35% lower than with 1.2 mm wire diameter [24].

2.1.6 Flux

A flux protects weld pool from atmospheric contamination and also provides alloying elements brings about desirable chemical changes to the weld metal and control the shape of the deposited metal. Fleck et al. [25] pointed out that filler wire and flux composition has a decisive role in formation of weld microstructure to achieve the desired properties in the weldment. Mechanical properties of the welds are improved for the fluxes containing TiO2 contents due to presence of acicular ferrite [26]. Figure 8 shows that with increases in titanium

content hardness increases which results in better mechanical properties [27].

2.1.7 Welding Polarity

Polarity is the direction of current flow. Harwig et al.[28]reported that polarity influences the amount of heat generated at the welding wire and work piece in the welding process which depends on direct current electrode positive (DCEP or reverse) or direct current negative polarity (DCEN or straight). There is more arc spread in straight polarity than in reverse polarity resulting in a higher bead width and less penetration. The two third of the total heat is generated at the positive welding wire and the one third of the total heat is generated at the negative welding wire [29]. Robinson [30] observed that DCEN has more electrode melting rate as compared to DCEP as shown in figure 9(a - b).

Figure 5: Effect of welding speed on bead width (after Yang et al. [16])

Bead

 

Wi

dt

h

 

(mm

)

 

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Area

 

of

 

he

at

 

affected

 

zone

 

(m

m

2 ) 

Wire feed rate (m/min)

Figure 6: Effect of wire feed rate on HAZ (after Murugun and Gunaraj [19])

Figure 7: Effect of wire diameter on melting rate (after Tuesk [23])

Wire diameter (mm)

Melting

 

rat

e

 

(kg

/h

)

 

Hardness

 

Va

lu

e

 

(H

v)

 

Titanium Percentage (%)

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3. Review of the Quality of Weld

Submerged arc welding is a welding process which is capable of welding thick material with high productivity. This process is suitable for welding of all sorts of low carbon steel, low alloy steel, stainless steel and heat resisting steels. Review of effect of submerged arc welding on quality of weld joint has been discussed below.

3.1. Parametric effect on weld bead geometry

In a welding process not only the productivity but bead geometry is also important. Weld bead geometry influences the mechanical properties of the welded joint but the weld bead geometry is further affected by welding parameters. Ghosh et al. [20] investigated that weld bead geometry is appreciably affected by input parameters. The findings show that increase of welding speed has a negative effect on weld bead parameters. An increase in penetration and marginal increase in reinforcement height is observed with increase in the current but the bead width decreased, however increase in arc voltage made the weld bead wider and flatter but decreases the penetration. Wire feed rate has a significant positive effect but welding speed has an appreciable

Figure 9.a: Effect of DCEN polarity on electrode melting rate (after Robinson [30])

Welding Current (Ampere) DCEN

   

    

Ele

ctrode

 

Melting

 

Rate

  

   

    

   

    

     

    

 

(g

/mi

n

)

 

Welding Current (Ampere) DCEP

Figure 9.b: Effect of DCEP polarity on electrode melting rate (after Robinson [30])

   

        

    

Elect

rode

 

Melting

 

Rate

  

   

    

   

    

     

    

 

(g

/mi

n

)

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negative effect on most important bead parameter penetration whereas arc voltage has a less significant negative effect on penetration and reinforcement which indicate that weld bead geometry is influenced by these process parameters [31]. Chandel et al. [5] studied the effect of increasing deposition rate on bead geometry of submerged arc welds suggested that smaller electrode diameter, negative electrode polarity and longer electrode extension can be used to increase the melting rate, further addition of metal powder and use of twin arc mode increases the deposition rate without increasing the given current. Metal deposition rate and welding arc efficiency are increased with the use of metal powder whereas shielding flux consumption is also reduced further optional chemical element can be alloyed to weld or cladding by the use of metal powder addition [32]. Mathematical model developed using fundamental welding parameters are helpful in predicting the deposition rate and quantifying the material loss during the twin wire submerged arc welding. Further it is revealed that predicted material loss is higher during DCEN than DCEP due to more heat generation at the electrode tip in DCEN [33]. DCEP polarity produced more penetration as compared to DCEN because in latter condition more filler metal is melted [34]. Benyounis and Olabi [35],while performing the study on optimization of different welding processes developed mathematical relationship between welding input process parameters and weld joint output parameters using statistical and numerical approaches and suggested that these approaches are useful for determination of welding input parameters which lead to desired weld quality.Taguchi methodology coupled with grey relational analysis is very useful in obtaining deeper penetration, reduced bead height and bead width [8]. Sensitivity analysis of submerged arc welding process parameter suggested that current is most important parameter in determining the penetration [36]. Taguchi methodology for optimizing the bead geometry and heat affected zone width in submerged arc welding also revealed that most influencing factor is current which has a positive effect on features of bead geometry and heat affected zone [37]. Datta et al. [38] while solving multi criteria optimization problem in submerged arc welding consuming fresh flux and fused flux found that all the parameters such as welding current, slag-mix percentage and flux basicity index significantly affect quality characteristics associated with bead geometry. Based on conducted experiments using fresh flux and fused slag at different levels it is concluded favourable weld quality in terms of bead geometry can be achieved using 10% slag mix [39]. Curvilinear equation equations are very helpful in providing useful information. It is estimated that metal loss through vaporization was 4% for electrode positive polarity and 8% for electrode negative polarity [40]. Yang et al. [41] while carrying out experimental analysis on effect of process variables on geometrical features of submerged arc welding found that linear regression equation are equally suitable for modelling the geometrical features of submerged arc welding as curvilinear equations because same correlation coefficient were obtained by both analysis. This feasibility study of use of linear regression equation was carried out for this purpose because due to low tolerance it was not possible to include all the variables in curvilinear regression analysis. Response surface methodology can be effectively used in analysing the cause and effect of process parameters on the response parameters [7].

3.2. Parametric effect on mechanical properties

The independent process parameters which influence the mechanical properties and can be controlled are voltage, current, stick out, wire feed rate and travel speed [17]. Kanjilal et al. [42] when focussed on combined effect of flux and welding parameters on chemical composition and mechanical properties of submerged arc weld metal found that polarity has a profound influence on weld metal chemical composition out of all other welding parameters. Further welding parameter mainly determined the weld metal yield strength and hardness whereas flux mixtures variable determined the impact toughness. Suitable regression models are found to be useful in predicting the transfer of elements such as oxygen, manganese, silicon and sulphur across the weld pool and chemical reaction related with submerged arc welding fluxes which affected the metal transfer [43]. Fluxes having SiO2, MnO and TiO2 content apart from main ingredients affected microstructure and tensile

properties of submerged arc welds. Yield strength and ultimate strength of the welds increase for the fluxes containing TiO2 contents due to presence of acicular ferrite. Hence selection of flux composition is important in

order to improve the mechanical properties of welds [26].Addition of titanium to the flux increased the titanium inclusion in the weld metal with a decrease in manganese rich inclusions that resulted in better impact toughness and microstructure [27]. Decrease in fracture appearance transition temperature and an increase in impact toughness has been observed by addition of molybdenum upto a particular range but presence of nickel alone in weld metal show a lower toughness and increase in fracture appearance transition temperature whereas combined presence of nickel and molybdenum in the weld metal lead to better toughness [44]. Jesus et al. [45] while studying influence of submerged arc welding process in mechanical behaviour of steel derived energy life relation by using the strain life data. These relations indicated that fatigue resistance of weld metal is defined in terms of strain energy of the cycle and is lower than as observed for base metal. Heat input influences the cooling rate, weld size and mechanical properties of the weld [46]. Kolhe and Datta [47] while performing

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microstructure. Microstructure and wear property study of alloy cladding by submerged arc welding revealed that presence of increased content of retained austenite in the microstructure results in lower hardness [48]. Crack susceptibility of carbon steel plates in submerged arc welding decrease as welding current decreases and welding travel speed or wire feed rate increases [49]. Postweld heat treatment practice of submerged arc welded steel resulted in reduction in mechanical properties of base metal and heat affected zone [50].So, metallurgical transformations result in weld residual stresses which affected the quality of the weld [51]. Mcpherson et al. [52] while performing experimentation on stainless steel found that use of high dilution submerged arc welding process for austenitic and duplex stainless steel has resulted in attaining acceptable properties of weld metal even with the use of high heat input. Heat input of 4.0 KJ/mm is sufficient for the having acceptable mechanical properties of the joint [53]. Process optimization by using the finite element analysis minimized the geometrical distortions, residual stresses and strains caused by submerged arc welding process [54]. Tarang et al. [55]during determination of submerged arc welding process parameters in hardfacing suggested that grey relational analysis can be used to convert optimization of multiple performance characteristics into single characteristics optimization called as grey relational grade. Fuzzy reasoning using taguchi method approach is also found to be novel and efficient for quality optimization of manufacturing systems with consideration of multiperformance characteristics because performance characteristics such as deposition rate and dilution are considered simultaneously and are improved through this study [56].

3.3. Parametric effect on heat affected zone

In submerged arc welding heat affected zone, required bead size and quality can be controlled by selecting the process variables.Murugunand Gunaraj [19] while predicting area of heat affected zone for bead on plate and bead on joint in submerged arc welding of pipes developed the mathematical model which can effectively control the area of HAZ by substituting appropriate values of process variables. Moeinifar et al. [57] on studying the effect of process parameters of tandem submerged arc welding on heat affected zone of welded specimen of high strength low alloy steel found that thermal cycles of tandem submerged arc welding has a significant effect on morphology of martensite and austenite constituents. Investigation of microstructure of submerged arc welded high strength low alloy steel joints revealed that increase in heat input coarsened the grain structures both in weld metal and heat affected zone [58], Further corrosion rates for weld metal and heat affected zone in acidic medium of HCL decreased with increase in heat input which affected the properties [59]. Mathematical models developed to predict the heat affected zone characteristics in submerged arc welding concluded that heat input and wire feed rate have a considerable positive effect on almost all heat affected zone dimensions. Welding speed has a negative effect on all heat affected zone dimensions whereas different HAZ layers increase with increase in arc voltage but no considerable effect of nozzle to plate distance is observed [60].

4. Discussion

Process variables strongly influence the weld bead geometry and microstructure of the welded joints in submerged arc welding. Composition of base metal, electrode wire and flux also imposes profound effect on the microstructure of weld metal. This can be realized by weld quality which is further assessed by weld bead characteristics. Further, Mechanical properties of the weld depend not only on composition of base metal but also on weld bead parameters and shape relationships which are mainly affected by the welding input parameters. Extensive work has been carried out by researchers to study and optimize the weld bead parameters. The findings of researchers revealed that apart from the welding current, arc voltage, travel speed, electrode stickout and flux which strongly affects the weld bead geometry, addition of metal powder also increases the deposition rate and improves the welding arc efficiency and reduces the shielding flux consumption. Further, chemical element can be alloyed to weld by the use of metal powder addition. Longer electrode extension can be used to increase the melting rate. The presence of acicular ferrite in submerged arc welds optimizes the toughness in the weld metal which is strongly affected by inclusion of titanium. So, Fluxes apart from main ingredients having contents of titanium oxide improve the mechanical properties. Hence it can be concluded that selection of welding input parameters is essential to control the properties of weld. Statistical and numerical approaches are useful for determination of optimized welding input parameters which lead to desired weld quality. Further process parameters should be chosen so as to achieve the minimum heat affected zone and least residual stresses and distortion. The following gaps in literature review have been revealed.

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2. The study of effect of polarity change on metal transfer behaviour in submerged arc welding is scarce. Polarity change affects the amount of heat generated at welding electrode and work piece and hence influences the metal deposition rate, weld bead geometry and mechanical properties of the weld metal. 3. Dynamic characteristics of an arc welding power source are determined by the transient variations in output

of current and voltage that appears in the arc. Negligible work on current voltage transient study in submerged arc welding has been reported.

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[57]Moeinifar, S.; Kokabi, A.H.; Hosseni, H.R.M. (2010): Effect of tandem submerged arc welding process and parameters of gleeble simulator thermal cycles on properties of the intercritically reheated heat affected zone, Material and Design, 32,pp.869-876.

[58]Prasad, K.; Dwivedi,D.K. (2006):Some investigation on microstructure and mechanical properties of submerged arc welded HSLA steel joints, International Journal of Advance Manufacturing Technology, 36, pp.475-483.

[59]Babu, K.S.P.; Natarajan, S. (2008): Influence of heat input on high temperature weldment in submerged arc welded power plant carbon steel, Material and Design, 29, pp.1036-1042.

Figure

Figure 1: Schematic arrangement of submerged arc welding
Figure 3: Effect of arc voltage on bead width (after Yang et al. [16])
figure 5 that with the increase in welding speed the bead width increases initially but it decreases with further in travel speed but reinforcement decreases to optimum value with increase in travel speed
Figure 6:  Effect of wire feed rate on HAZ (after Murugun and Gunaraj [19])
+2

References

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