Weld-cost saving accomplished by replacing single-wire submerged arc welding with triple-wire welding

Abstract

A comparison is made of different submerged arc welding processes, that is ones using singlewire, twin-wire and triple-wire electrodes, applied to welding of two webs consisting of L sections 16x90x4100 mm in size. Experimental welding, measurement of welding parameters, calculation of the melting rate, measurement and calculation of shielding flux consumption, a visual examination of the welds made, an analysis of macro sections, and an economic calculation of the respective total cost of the welding processes using single-wire, twin-wire and triple-wire electrodes were performed in order to make a comparative analysis of the processes concerned. The experimental results obtained showed that high quality welded joints could be produced using two wires or three wires, i.e. the twin- or triple-wire electrode, in a joint contact tube in submerged arc welding. The calculation of the cost-effectiveness of welding, including personnel, materials, overheads and other costs, showed that welding with the twin-wire electrode cuts the costs by 20% and welding with the triple-wire electrode by around 30%. Submerged arc welding with a triple-wire electrode is a new welding process variant suitable for thick and long workpieces and in cases where a larger quantity of the molten filler material is required. Three wires in a joint contact tube can be arranged in a line or in the shape of a triangle optionally with long sides depending on the shape of the joint assembly and the weld shape desired. Although this procedure is highly efficient and shows numerous advantages over welding with a single-wire electrode, it has not been established in practice yet.

Avaliação do Uso do Tecimento na Soldagem a Arco Submerso

“…Contudo, é constante o desenvolvimento de técnicas de soldagem com o intuito de aprimorar este processo a fim de atingir o máximo de desempenho e, assim, aumentar a taxa de deposição possível de ser conseguida e/ou obter melhores propriedades mecânicas da junta soldada atrelado a esta alta capacidade de deposição. Neste contexto, é possível encontrar na literatura uma grande quantidade de trabalhos que abordam o emprego de diversas técnicas de soldagem no processo SAW, como a utilização de múltiplos arames [2][3][4][5][6], em configurações conhecidas como "twin-arc" ou "tandem-arc", o emprego …”

Review of the Recent Trends of Process Monitoring and Control for Double- Wire GMAW Process

“…As the most investigated and frequently employed multiwire welding technology, double-wire formed arc welding was first proposed in the middle of the last century, and was used in submerged arc welding [4]- [6]. However, because of the particular characteristics, the double-wire submerged arc welding can only be applied in flat position of welding.…”

Cost Analysis and Waste Reduction of Reclaimed Slag over Fresh Flux in Submerged Arc Welding

“…From literature review, it was found that flux ensured the composition as 30% (SiO2zTiO2), 55% (Al2O3zMnO), 5% CaF2, and 10% binding material. The metallurgical blending of wire and flux was same in most of recycled technique [1]. The physical properties of fresh flux are very important factor in submerged arc welding for enhancing the welding properties.…”