Advanced Manufacturing Processes

Advanced Welding Processes

Dr. D.V. Kiran and Dr. N. Venkaiah

Department of Mechanical Engineering,

Indian Institute of Technology Tirupati

06th March, 2019

Submerged Arc Welding (SAW) Process
• It uses heat generated by an arc struck
between bare consumable electrode wire and
the work piece.
• The arc and the weld zone are completely
covered under a blanket of granular fusible flux.

• During welding, this flux melts and provides

protection to the weld pool from the
atmospheric gases.

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Applications of SAW Process

Thick plate joining Pipe joining

Gas cylinders Pressure vessel

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Applications of SAW Process

Spiral pipe welding

Ship building

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Advanced Variants of submerged Arc Welding Process
(1) Waveform controlled SAW process (2) Tandem SAW process

Waveform controlled SAW process

Influence of wave balance Influence of wave offset

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Advanced Variants of submerged Arc Welding Process
(1) Waveform controlled SAW process (2) Tandem SAW process
Tandem SAW process

• Two wires are independently controlled by separate power sources and one leads the
other along the weld seam.
• The front wire is called the leading wire (DCEP) and the rear wire is called trailing wire
(waveform controlled AC).

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Advanced Variants of submerged Arc Welding Process
(1) Waveform controlled SAW process (2) Tandem SAW process
Tandem SAW process configuration

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Advanced Variants of submerged Arc Welding Process
(1) Waveform controlled SAW process (2) Tandem SAW process

Tandem SAW process

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Advanced Variants of submerged Arc Welding Process
Tandem SAW process
Ex) Leading arc: 1000A, 32V,
Trailing arc: 1000A, 35V

The same polarities - Attraction The opposite polarities - Repulsion

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