ADVANCE WELDING 11

i. Explain electro slag welding.

ii. Explain the uses of electro slag welding.

iii. list four materials that can be welded by electro slag welding.

2i. Explain dilution in electro slag welding.

ii. What influence does the contact tube to work distance have over the weld bead in electro slag
welding?

iii. Explain the principle of operation for electro slag welding?

3i. List four advantage of electro slag welding.

ii. state two types of electrode used in electro slag welding.

iii. Explain the function of the flux in electro slag welding.

4i. Explain submerge arc welding.

ii. State four ways that can be used to minimize distortion caused by shrinkage.

iii. state two types of flux use in submerge arc welding

Solution

1. Electro Slag Welding (ESW)

ESW is a high-productivity welding process used for joining thick materials in a vertical or near-
vertical position. It involves creating a molten slag pool between the workpieces using an electric
arc. The slag, heated by electrical resistance, melts the electrode and workpiece edges, forming a
weld.

2. Uses of Electro Slag Welding

 Joining thick sections of steel in a single pass

 Welding heavy structural components like ship hulls, pressure vessels, and offshore
structures
 Cladding of metal surfaces for wear resistance or corrosion protection
 Repairing large-scale defects in castings and forgings

3. Materials Weldable by ESW

  Carbon steels
 Low alloy steels
 Stainless steels
 Nickel alloys
 Copper alloys

2. Dilution in Electro Slag Welding

Dilution is the degree to which the base metal is mixed with the filler metal in the weld. In ESW,
dilution is generally low due to the high melting rate of the electrode and the protective nature of
the slag. Factors affecting dilution include electrode composition, welding current, and travel
speed.

2. Influence of Contact Tube to Work Distance

The contact tube to work distance affects the heat input and weld bead geometry. A shorter
distance results in higher heat input, leading to a wider and deeper weld bead. A longer distance
reduces heat input, resulting in a narrower and shallower weld bead.

2. Principle of Operation

ESW works by creating a molten slag pool between the workpieces. An electric arc is initially
struck to melt the flux, forming the slag pool. Once the arc is extinguished, the electric current
passes through the conductive slag, generating heat. This heat melts the electrode and workpiece
edges, forming the weld.

3. Advantages of Electro Slag Welding

 High deposition rate

 Ability to weld thick sections in a single pass
 Low distortion
 Good mechanical properties of the weld
 Reduced labor costs compared to manual welding

3. Types of Electrode

 Solid wire electrode

 Tubular wire electrode

3. Function of Flux

 Protects the weld pool from atmospheric contamination

 Provides deoxidizers and alloying elements
 Conducts electricity to maintain the molten slag pool
 Stabilizes the arc (in some cases)
Submerged Arc Welding (SAW)
4. Submerged Arc Welding (SAW)

SAW is a high-productivity arc welding process where the arc is submerged beneath a granular
flux. The heat from the arc melts the electrode and base metal, while the flux protects the weld
from the atmosphere.

4. Ways to Minimize Distortion

 Proper joint design

 Balanced weld sequence
 Use of backing bars
 Post-weld heat treatment

4. Types of Flux

 Oxidizing flux
 Reducing flux

QUESTION 2

1. Explain the principle of operation of eletro slag welding.

2. State the two variations of electro slag welding?
3. What is the purpose of flux in electrosalg welding.
4. Discuss the power supply of electro slag welding.
5. Explain in details the function of wire feeder in electro slag welding.
6. Discusss why preheating and post heating is not necessary in electro slag welding.
7. Explain the function of flux in electro slag welding.
8. Discuss the principles of operation of submerge arc welding welding.
9. State two types of flux used in submerge arc welding.
10. Mention four advantages of fused flux.
11. Discuss four power source for submerge arc welding.
12. Mention four accessories equipment commonly used for submerge arc welding .
13. List four hazards that a welding operator may encounter around robotic work station.
Solution

1. Principle of Operation of Electro Slag Welding

Electro slag welding (ESW) is a fusion welding process where heat is generated by passing an
electric current between a consumable electrode and the workpiece through a molten slag
covering the weld surface. The process involves:

 Arc initiation: An arc is struck between the electrode and the workpiece to melt the flux.
 Slag formation: The molten flux forms a liquid slag pool.
 Heat generation: The electric current passing through the highly resistive molten slag
generates heat.
 Metal melting: The heat melts both the electrode and the workpiece edges.
 Weld formation: Molten metal droplets from the electrode fall into the weld pool,
forming a weld bead.
 Slag removal: As the weld progresses, the solidified slag is removed.

2. Two Variations of Electro Slag Welding

 Single-wire ESW: Uses a single electrode wire.

 Multi-wire ESW: Employs multiple electrode wires for higher deposition rates.

3. Purpose of Flux in Electro Slag Welding

 Heat generation: Provides electrical resistance to generate heat.

 Shielding: Protects the molten weld pool from atmospheric contamination.
 Slag formation: Creates a liquid slag pool to facilitate the welding process.
 Alloying: Can introduce alloying elements into the weld metal.

4. Power Supply of Electro Slag Welding

ESW requires a high current, low voltage DC power source. The power source should be capable
of supplying a stable current to maintain the molten slag pool.

5. Function of Wire Feeder in Electro Slag Welding

The wire feeder:

 Continuously supplies electrode wire to the welding process.

 Maintains a constant wire feed rate to ensure consistent weld bead formation.
 Controls the electrode wire position and orientation.
 Often incorporates a water-cooling system to prevent overheating.

6. Preheating and Post Heating in Electro Slag Welding

Preheating and post heating are generally not required in ESW due to:

 High heat input: The process generates sufficient heat to prevent cracking.
 Thick sections: ESW is primarily used for thick sections, which have lower cooling
rates.
 Molten slag: The slag pool acts as an insulating layer, reducing heat loss.

7. Function of Flux in Electro Slag Welding (repeated for clarity)

 Heat generation: Provides electrical resistance to generate heat.

 Shielding: Protects the molten weld pool from atmospheric contamination.
 Slag formation: Creates a liquid slag pool to facilitate the welding process.
 Alloying: Can introduce alloying elements into the weld metal.

Submerged Arc Welding (SAW)

8. Principles of Operation of Submerged Arc Welding

SAW is a fusion welding process where an electric arc is struck between a continuously fed
consumable electrode and the workpiece. The arc is submerged beneath a granular flux, which
melts to form a slag cover protecting the weld pool from atmospheric contamination.

9. Two Types of Flux Used in Submerged Arc Welding

 Fused flux: Produced by melting and granulating flux materials.

 Agglomerated flux: Produced by pressing and sintering flux materials.

10. Four Advantages of Fused Flux

 Consistent chemical composition.

 Fine particle size for better arc shielding.
 Good fluidity for slag removal.
 Higher melting point for better slag stability.

11. Four Power Sources for Submerged Arc Welding

 DC power supply (straight polarity)

 AC power supply
 High frequency power supply
 Pulse power supply

12. Four Accessory Equipment Commonly Used for Submerged Arc Welding

 Wire feeder
 Flux hopper
  Tractor or carriage
 Control panel

13. Four Hazards That a Welding Operator May Encounter Around a Robotic
Workstation

 Robot movement hazards: Collisions with the robot or its components.

 Arc flash and radiation hazards: Exposure to intense light and heat.
 Fume and gas inhalation hazards: Exposure to welding fumes and gases.
 Noise hazards: Exposure to high noise levels from robot operation.