Robotic Automation Of Submerged Arc Welding

This video explores the often-underrated Submerged Arc Welding (SAW) process, highlighting its advantages and showcasing how robots can unlock their full potential in heavy fabrication.

The Power of SAW:

High Deposition Rates: SAW boasts unmatched welding speeds, translating to significant productivity gains.
Excellent Weld Quality: The submerged arc creates a clean, oxide-free weld due to the protective flux covering.
Deep Penetration: SAW offers deep weld penetration, which is crucial for robust welds in thick materials.
Limited Applications: SAW is primarily used for flat and horizontal welds on ferrous steel and nickel alloys.
Challenges and Overcoming Them:

Limited Positional Versatility: Traditionally, SAW is limited to flat welds due to the reliance on gravity for flux placement.
Robot Integration: SAW can be cumbersome to automate due to flux handling requirements.
Robots to the Rescue:

Robots overcome the limitations of SAW by:

Enabling Complex Weld Paths: Robots can manipulate the torch to achieve welds on non-flat surfaces, expanding application possibilities.
Precise Control: Robots provide consistent and precise torch positioning, ensuring optimal weld quality.
Continuous Welding: Robots eliminate weld starts and stops, reducing potential defects and boosting productivity.
Real-world Applications:

The video showcases impressive examples of robotic SAW in action, including:

Large Diameter Pipe Welding: Robots seamlessly weld large pipes with continuous SAW.
Complex Flange Welding: Robots tackle intricate flange geometries with precise torch control.
Additive Manufacturing: SAW with robots creates defect-free, high-deposition rate additively manufactured parts.
Block Preventer Ram Bore Welding: Robots navigate curved surfaces to achieve continuous welds in critical ram bore cavities.
Conclusion:

By combining the power of SAW with robotic automation, manufacturers can achieve significant gains in productivity and weld quality for heavy fabrication projects. This video presentation effectively demonstrates the potential of this often-overlooked welding technique.