Welding Consumables

SAW

Submerged arc welding (SAW)

 
 
In weld cladding, in contrast to seam welding, the material to be applied is preferably fed in as a strip electrode. Otherwise, the process descriptions provided in the chapter “Submerged arc welding” apply.
 
Technical prerequisites
  • Submerged arc power source (direct current)
  • Welding flux with targeted composition and tested quality
Welding material
Cold-rolled strip in standardized analysis, standard dimension 90 x 0.5 mm, 60 x 0.5 mm or 30 x 0.5 mm (3.54 x 0.02 in, 2.36 x 0.02 in or 1.18 x 0.02 in), strip electrode in positive polarity. Because of the higher deposition rate, automatic strip cladding requires current intensity up to approx. 700 A at voltages around 30 V. Welding speeds of approx. 12 cm/min (4.7 in/min) are usual.
 
Processing instructions
All work pieces should be free of contaminants (especially anything containing sulphur). A run-on plate should be used for the ignition of the electric arc.

ES

Electroslag welding (ES)

 
Electroslag weld cladding is similar to the submerged arc weld cladding process. However, the heat required for welding is not provided by an arc, but by passing electrical current through melted electroslag. An electric arc is only used at the beginning of the process until a sufficient amount of electroslag is melted. After this, because of the rising amount of slag, the larger contact surface with the backing and the rising slag temperature, the electrical resistance of the slag falls until the arc finally goes out. The weld heat during the actual welding process is then only produced by conductive heating caused by current transfer through the liquid slag. The temperature of the slag at this point is approx. 2000 °C (3632 °F).
 
Technical prerequisites
  • Welding material and processing instructions comparable to submerged arc weld cladding
  • ES flux

MAG tandem

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Gas-shielded MIG/MAG

Gas-shielded metal-arc welding MIG/MAG
 

In MIG/MAG weld cladding, the same process is followed as in MIG/MAG joint welding, except that the wire electrodes can be woven during welding. In addition, it is also possible, by using a current-free, so-called cold wire, to increase the deposition rate and achieve better heat management for the welding process.
 
Technical prerequisites
  • A pulse current source
  • Inert or corresponding MAG shielding gas with a pre-defined CO2 percentage
  • A wire electrode