ARC Welding

Submerged arc welding (SAW) is a semi-automated welding technique used by Caterpillar. It feeds a bare wire electrode into an arc, covered by granular flux. This process improves welding quality and efficiency. It is particularly beneficial for heavy machinery components, like those found in Caterpillar’s D11 idler parts. The equipment operates with a continuous wire … Read more

Ceramic backings offer benefits in submerged arc welding. They enhance weld quality and improve bead formation. They are cost-effective for MAG welding and solid wire applications. The backings trap slag, protecting the welds. Commonly used in shipbuilding and heavy manufacturing, they streamline processes and lower grinding costs. One of the key benefits of Submerged Arc … Read more

In submerged arc welding, common defects include porosity and cracking. Porosity involves gas bubbles trapped in the weld, weakening welding strength. Cracking results in fissures that can lead to structural failure. Recognizing these issues is crucial for maintaining welding integrity and performance. To troubleshoot these issues, begin by examining the welding parameters. Insufficient heat can … Read more

Submerged Arc Welding (SAW) has several classifications. These include wire types like solid (‘E’) and composite (‘EC’), as defined by AWS standards. Flux types can be fused, agglomerated, or mixed. SAW is suitable for carbon steels, low alloy steels, stainless steels, and nickel-based alloys in various applications. Applications of submerged arc welding span diverse industries, … Read more

Submerged arc welding components include the welding head, which delivers the electrode, and the flux hopper that feeds flux. The flux protects the weld pool during the process. The electrode generates the arc needed for welding. Together, these parts ensure an efficient welding operation within a protective atmosphere. The process begins with the welding machine … Read more

Plasma arc welding of copper and copper alloys can be done without filler metal or with it. When using filler metal, the options are similar to those in Gas Tungsten Arc Welding (GTAW). This process improves efficiency through automation and reduces contamination risks compared to traditional GTAW methods. The process encourages precise control over weld … Read more

Submerged arc welding (SAW) creates strong, uniform, and ductile welds that resist corrosion and have high impact values. It efficiently welds thick plates in a single pass using standard equipment. The process uses flux to shield the welding arc, reducing spatter. Additionally, 50% to 90% of the flux can be recycled and reused. The equipment … Read more

In arc welding, the welder turns on the power supply and holds the electrode close to the base material. An electric arc creates intense heat, melting both the base metal and the electrode core. The flux coating shields the weld area, protecting it from contamination. This process ensures a strong bond between the materials. To … Read more

Staring at a welding arc can lead to eye damage, called arc-eye or welder’s flash, due to ultraviolet (UV) radiation. This radiation can burn the cornea and skin. You should always wear safety glasses for protection. Symptoms may improve with rest and treatment within a few days. Prioritize eye and skin safety during welding. Immediate … Read more

To start a welding arc, tap the rod tip sharply on the workpiece. This removes excess flux from the rod’s end. Use a quick wrist motion for momentary contact with the surface. After tapping, pull the rod slightly away to create a stable arc. This technique effectively initiates the welding process. Next, strike the electrode … Read more