Скачать или смотреть Case 4 - Reliable SAW Welding in Monsoon-Affected Pipe Fabrication

Application
This case features a pipe manufacturing customer performing longitudinal seam and circumferential seam welding. Plates are rolled to the required pipe diameter, followed by MMAW root run and SAW fill and cap runs using a trolley-mounted SAW machine.

Challenge
Welding was carried out in an open shed during monsoon season, where:
• Moisture contamination was unavoidable
• Base metal and wire were prone to rusting
• Environmental control was limited

To enable stable welding, a flame torch was used prior to welding to reduce moisture in the steel; however, rust remained on the surface, as visible in the images. Such conditions typically disrupt arc stability and slag behaviour in SAW Welding

Flux Solution
Despite severe monsoon exposure, AV EZEWELD 18L delivered stable welding performance, demonstrating strong tolerance to moisture-related challenges common in open-shop pipe fabrication.

Welding Details
• Process: SAW (after MMAW root run)
• Machine: Trolley-mounted SAW
• Joint Types: Longitudinal seam & circumferential seam
• Wire: EL8 – 4.0 mm
• Voltage: 36–40 V
• Current: 500–600 A
• Trolley Speed: 400–500 mm/min
• Pass Sequence: MMAW root run + two SAW runs

Observed Performance
• Stable arc despite monsoon moisture
• Controlled slag behavior with easy removal
• Uniform weld bead profile on both seam types

Outcome
The customer achieved consistent pipe weld quality during monsoon conditions, confirming AV EZEWELD 18L as a dependable SAW flux for open-shed pipe welding where moisture control is difficult.