1. One Side Welding Submerged Arc Welding Process Welding in Shipbuilding Conference May 10-11, 2011 by Sean P Moran

2. Outline of Presentation  Introduction of the Process  Procedure for Application  Weld Evaluation Results  Supporting Discussion  Summary

3. Introduction of the Process  Submerged Arc Welding (SAW) Application  Multiple Wire Tandem Procedure  Single (One) Side Full Penetration Welds  Weld Travel Speeds Capable of 60 IPM

4. Advantages, SAW-OSW  Reduce Production Time  Eliminate the Additional Cost of Equipment Needed to Rotate the Plates for Two-Sided Welds  Capable of Achieving Full-Penetration Square Butt Seams in ¼” Plate From One Side  Excellent Welder Appeal – Ease of Use

5. Limitations, SAW-OSW  Limited Fit Up Robustness  Fixture and Clamping  Flux Bed Mechanism and Procedure  Multiple Weld Head Requirements

6. Procedure for Application  Tandem Welding Process using DC Lead and AC Trail  Solid Wire Lead using Solid and Tubular Wire Trail  Square Butt Joint Preparation with 0 – 1/8 Gaps  Non-Floating 1½” Width and 9/32” Depth Flux Bed  Copper Chill Bar with 1½” x 1/16” Center Recess

7. Weld Joint Fit Up  Two ¼” x 2” x 18” hot rolled plates with ¼” x 2” x 9 run off tabs at either end  Set two 18” bars side by side, set the gap, weld tabs and 3 tack welds at ¼, ½ & ¾ of plate length

8. Equipment Selection  PEH Controls  LAF 1000 DC  TAF 800 AC  A6 Wire feeders  Knurled Feed Rolls for (Tubular Wire)

9. Equipment Set Up  Electrode angle 90º Lead 65º Trail  3/4" Distance between electrodes

10. Welding Consumables  DC/AC - 1/8” Spoolarc 81 Solid Wire EM12K  DC/AC - 1/8” Alloy Shield 70S Tubular Wire EC1-H8  Welding Flux: OK Flux 10.71 F7A5  Backing Flux: OK Flux 10.69 No AWS Classification

11. Application Set Up  2½” x 1½” x 6’ copper chill with 1½” x 1/16” center recess  OK Flux 10.69 applied over the top of the chill  Excess flux screen off forming a 7/32” crown

12. Welding Parameters Spoolarc 81 Solid Wire Lead and Trail GapDC Lead AC Trail Travel InchAmpsVoltsAmpsVoltsIPM 0 700295503458 1/16 700296003558 3/32 425296003250 1/8 N/A Spoolarc 81 Solid Wire Lead and Alloy Shield 70S Trail 0 700295503458 1/16 700296003558 3/32 425296003250 1/8 N/A

13. Weld Evaluation Results Spoolarc 81 Solid Wire Lead and Trail Gap WidthTravel SpeedResults 0” 58 IPMTop - easy peeling - straight edges Bottom - medium bead, good edges, easy peeling 1/16” 58 IPMTop - easy peeling medium reinforcement Bottom - medium bead, easy peeling 3/32” 50 IPMTop - almost flat - self peeling Bottom - medium bead - slightly uneven Spoolarc 81 Solid Wire Lead and Alloy Shield 70S Trail 0” 58 IPMTop – self peeling - medium reinforcement - smooth Bottom - medium bead- smooth - self peeling 1/16” 58 IPMTop - self peeling - medium reinforcement - smooth Bottom - medium bead- smooth - self peeling 3/32” 50 IPMTop - smooth medium reinforcement - self peeling Bottom - medium bead- slightly uneven - self peeling

14. Macro-Sections - No Gap

15. Macro-Sections – 1/16 Gap

16. Macro-Sections - 3/32 Gap

17. Supporting Discussion  Travel Speeds Approaching 60 IPM  Excellent Full Penetration Profiles  Increase Face Reinforcement with Tubular Wire  Gap Size of 1/8” Prove to Have Limited Robustness

18. Future Work  Varying Gap Width of 0 -.5T  Increase and Alter Electrode Diameters  Robust.5T Full Length Gap  Evaluate Mechanical Weld Properties

19. Summary  One Sides Full Penetration SAW  Tandem with Either Solid or Tubular Trail  Robust Gap Widths of 3/32 inch  Weld Travels Speeds Approaching 60 IPM  User Friendly - Ease of Operator Use