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Describe, with the aid of a diagram(s), the features of the submerged arc welding process shown, with reference to equipment, operation and applications. - Leaving Cert Engineering - Question c - 2020
Question c
Describe, with the aid of a diagram(s), the features of the submerged arc welding process shown, with reference to equipment, operation and applications.
Worked Solution & Example Answer:Describe, with the aid of a diagram(s), the features of the submerged arc welding process shown, with reference to equipment, operation and applications. - Leaving Cert Engineering - Question c - 2020
Step 1
Equipment Features
Answer
In submerged arc welding (SAW), key equipment includes:
- Bare Wire Electrode: A continuous solid wire that provides the filler material necessary for welding. It is automatically fed from a spool during the process.
- Flux: A powder that is fed from a hopper, which covers the welding area. It protects the weld and helps in smoothing the weld surface.
- Hopper: This component stores the flux and ensures a consistent supply to the welding area.
- Control Unit: It manages the automated functions of the welding system, ensuring proper voltage and current for effective welding.
Step 2
Operation Features
Answer
The operation of submerged arc welding entails the following steps:
- The bare wire electrode is fed automatically into the welding zone.
- An electric arc is generated between the electrode and the workpiece, which heats the metal to its melting point.
- The flux, when it contacts the molten metal, forms a protective slag layer, preventing oxidation and contamination.
- Excess flux can be collected and reused, making the process efficient and cost-effective.
- This method is fully automated, which enhances productivity and consistency in welding quality.
Step 3
Applications
Answer
Submerged arc welding is particularly suited for:
- Large Scale Welds: Ideal for straight line welds common in construction contexts, able to cover extensive lengths quickly.
- Structural Applications: Often utilized in steel fabrication, such as reinforcing beams and large scale shipbuilding projects.
- Bridge Construction: Effective in creating strong, durable connections in large metal structures, ensuring safety and longevity.