Optimization and Performance Analysis of Submerged Arc Welding: Influence of Bead Geometry, Process by IRJET Journal

Optimization and Performance Analysis of Submerged Arc Welding: Influence of Bead Geometry, Process Parameters, and Heat-Affected Zone- A review

Prof. A. V. Patel 1 , Prof. V. P. Patel 2 , Prof. Puneet Bansal 3 , Prof. B. V. Bhuva 4 1, 2, 3, 4, Assistant Professor, Department of Mechanical Engineering, U.V.P.C.E, Kherva, India 384012

Abstract - Submerged arc welding (SAW) is a widely used process in industrial applications due to its high efficiency and deep penetration capabilities. This study reviews the impact of bead geometry, process parameters, and the heat-affected zone (HAZ) on weld quality. Research findings indicate that increasing deposition rates influence bead width, height, and penetration, affecting overall weld performance. Multiple-wire SAW with metal powder addition enhances deposition efficiency and reduces defects. Optimization techniques, such as the Taguchi method and response surface methodology, have been applied to refine bead geometry, HAZ width, and overall weld properties. The chemical composition of flux and welding wire significantly impacts microstructure, mechanical properties, and element transfer behavior. Studies also show that heat input and travel speed directly affect grain structure, hardness, and toughness in welded joints. Proper selection of welding parameters, flux composition, and wire material is essential for achieving optimal weld strength, toughness, and durability. These findings provide valuable insights for improving SAW techniques in various industrial applications

Key Words: SubmergedArcWelding,BeadGeometry,HeatAffected Zone, Welding Parameters, Flux Composition, MechanicalProperties,OptimizationTechniques

1. INTRODUCTION

Submerged Arc Welding (SAW) is a high-efficiency arc weldingprocessthatcanbeperformedinautomaticorsemiautomatic modes. It is widely utilized in industrial applications due to its high deposition rate, deep penetration, and consistent weld quality. Unlike conventional arc welding methods, SAW operates by maintaining an arc between a bare consumable electrode andtheworkpiece,whileagranularfluxcompletelycovers thearc,makingitinvisibleduringwelding.Thissubmerged arctechniquesignificantlyreducesheatlossandenhances thermalefficiency,reachingupto90%. (1)

Theprocessisbestsuitedforhorizontalweldingpositions, ensuring smooth and uniform weld bead formation. To maintain process consistency, SAW requires an automatic wirefeedmechanism,aconstantvoltagepowersource,and digital controls. The granular flux, continuously supplied from a hopper, acts as a protective barrier against atmosphericcontamination,improvingweldintegrity.Asa

result,SAWweldsexhibithighstrength,excellentductility, andminimalhydrogenandnitrogencontent,makingthem idealforstructuralandheavy-dutyapplications.

Thisweldingtechniqueiscommonlyapplied inindustries thatrequirebuttjointsandfilletweldswithgrooves,suchas automobilemanufacturing,railwayequipmentproduction, shipbuilding, structural engineering, pressure vessel fabrication, pipeline welding, and storage tank manufacturing. The quality ofSAW weldsdepends on key processvariables,includingweldingcurrent,voltage,travel speed, and flux composition. Careful control and optimization of these parameters are essential for minimizingdefects,refiningbeadgeometry,andenhancing mechanicalproperties. (2)

Themechanicalpropertiesofaweldareinfluencedbythe basemetal compositionand significantlyaffected by weld beadgeometry,whichisshapedbybothdirectandindirect weldingparameters.Inadditiontoproductivity,weldbead geometryplaysacrucialroleindeterminingthemechanical strengthoftheweldment,promptingextensiveresearchon theimpactofprocesscontrolparameters.Keycontrollable factors such as voltage, current, electrode stick-out, wire feed rate, and welding speed directly influence hardness, yield strength, impact toughness, and ultimate tensile strength (UTS). Studies indicate that increasing electrode stick-outraisesweldhardnesswhilereducingyieldstrength andimpacttoughness,withUTSinitiallydecreasingbefore increasingunderconstant weldingcurrentandvoltage.In submergedarcwelding(SAW),preciseselectionofprocess variables is essential for controlling heat-affected zone (HAZ)dimensionsandachievingthedesiredbeadsizeand quality.ThethicknessofdifferentHAZlayersincreaseswith highervoltage,wirefeedrate,andheatinputbutdecreases withincreasedweldingspeed.Properoptimizationofthese parametersenhancesweldstrength,durability,andoverall performanceinindustrialapplications.

2. LITERATURE REVIEW

2.1

EFFECT OF BEAD GEOMETRY ON THE QUALITY OF WELD:

R.S. Chandel, H.P. Seow, F.L. Cheong while predicting the impactofincreasingdepositionratesonthebeadgeometryin

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056

Volume: 12 Issue: 03 | Mar 2025 www.irjet.net p-ISSN: 2395-0072

submergedarcwelding.Itanalyzeskeyparameterssuchas bead width, height, and penetration. Results indicate that higher deposition rates lead to wider and shallower weld beads, affecting overall weld quality. The findings help optimize welding parameters for improved efficiency and performance.(3)

J.Tusek, M. Suban while dealing with high-productivity multiple-wire submerged arc welding and cladding with metal-powderaddition.Itexamineshowprocessparameters influence weld quality, efficiency, and material properties. Theresultsshowthatusingmultiplewiresandmetalpowder increases deposition rates, improves weld bead characteristics,andenhancesoverallproductivity.Thestudy also highlights a reduction in defects and better material utilization.Additionally,itdiscussestheadvantagesofthis technique in industrial applications. The findings help optimize welding processes for higher efficiency and performance.(4)

K.Y.Benyounis,A.G.Olabiwhiledealingwithoptimization techniquesforvariousweldingprocessesusingstatisticaland numerical approaches. It explores methods like response surfacemethodology,Taguchitechniques,andfiniteelement analysistoenhanceweldqualityandefficiency.Theresearch highlightskey weldingparameters,suchas heatinputand welding speed, that influence performance. Applications across different welding methods, including arc and laser welding, are discussed. The findings show that these optimization techniques help reduce defects, improve productivity,andlowercosts.Thisstudyservesasavaluable resource for researchersand engineers aiming to enhance weldingprocesses.(5)

Serdar Karaoğlu and Abdullah Seçgin while dealing with analyzes the sensitivity of key process parameters in submerged arc welding and their impact on weld quality. Parameterssuchasvoltage,current,weldingspeed,andwire feed rate are evaluated. Results show that these factors significantly influence bead geometry, penetration, and overallweldperformance.Sensitivityanalysishelpsidentify the mostcritical parameters for process optimization. The studyprovidesvaluableinsightsforimprovingweldquality, efficiency,andconsistency.Thesefindingsassistindustriesin refiningsubmergedarcweldingtechniquesforbettercontrol andproductivity.(6)

L.J.Yang,R.S.ChandelandM.J.Bibby,whileinvestigatingthe effectsofprocessvariablesonbeadwidthinsubmergedarc welding.Itexamineskeyparameterssuchasweldingcurrent, voltage,travelspeed,andelectrodediameter.Resultsshow thathighercurrentandvoltageincreasebeadwidth,while greater travel speed reduces it. The study establishes empirical relationships between these variables and bead geometry. This understanding helpsin optimizing welding parametersforimprovedweldqualityandconsistency.The findingscontributetobettercontroloftheweldingprocessin industrialapplications.(7)

2.2 EFFECT OF PROCESS PARAMETERS ON THE QUALITY OF WELD:

P.Yongyutph,K.Ghoshp,C.Guptaa,K.PatwardhaandSatya Prakash while studying study investigates how macrostructureandmicrostructureaffectthetoughnessof multipass submerged arc welded C-Mn steel deposits. It examinesfactorssuchasgrainsize,phasedistribution,and heat-affected zones. The resultsshowthat microstructural variationssignificantlyinfluencetoughness,withfinergrain structures generallyimproving it. Thestudy highlights the importance of controlling welding parameters to achieve optimal structural characteristics. It also emphasizes the relationship between weld morphology and mechanical performance. These findings provide valuable insights for optimizing welding techniques to enhance toughness and durability.Theresearchisparticularlyusefulforindustries utilizingC-Mnsteelinstructuralapplications.(8)

N.D.Pandey,A.BhartiandS.R.Gupta whilestudyingstudy investigateshowsubmergedarcweldingparametersandflux compositionsinfluenceelementtransferbehaviorandweldmetalchemistry.Itexaminesfactorssuchasweldingcurrent, voltage, travel speed,and flux type. Resultsshow that flux compositionsignificantlyaffectsthetransferofelementslike manganese, silicon, and sulfur through oxidation and deoxidation reactions. The study emphasizes the role of weldingparametersincontrollingweld-metalcomposition and overall quality. Proper selection of fluxesand welding conditionsisessentialforachievingdesiredweldproperties. These findings help optimize submerged arc welding for improved performance and consistency in industrial applications.(9)

P.Kanjilal,T.K.PalandS.K.Majumdar,whiledoingexamines the combined effect of flux composition and welding parameters on the chemical composition and mechanical properties of submerged arc weld metal. It analyzes key factors such as welding current, voltage, travel speed, and fluxtype.Resultsshowthatbothfluxandprocessparameters significantlyinfluenceelementtransfer,weld-metalstrength, andtoughness.Thestudyemphasizestheneedforoptimal flux selection and welding conditions to achieve desired mechanical properties. Proper control of these factors enhancesweldqualityandminimizesdefects.Thefindings provide valuable insights for improving submerged arc weldingperformanceinindustrialapplications.(10)

De-liangRen,Fu-renXiao,PengTian,XuWangandBoLiao, while conducting investigates the effects of welding wire composition and welding process parameters on the weld metaltoughnessofsubmergedarcweldedpipelinesteel.It examineshowvariationsinalloyingelementsandwelding conditions influence the microstructure and mechanical properties of the weld. Results show that welding wire compositionsignificantlyaffectstoughnessbyalteringgrain structure and phase distribution. The study highlights the importance of optimizing welding parameters to enhance

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056

Volume: 12 Issue: 03 | Mar 2025 www.irjet.net p-ISSN: 2395-0072

weld metal performance. Proper selection of welding wire andprocessconditionsimprovestoughnessandoverallweld quality. These findings provide valuable insights for improving submerged arc welding in pipeline applications.(11)

Ana Ma. Paniagua-Mercado, Victor M. López-Hirata and Maribel L. Saucedo Muñoz, while study examines how the chemicalcompositionoffluxinfluencesthemicrostructure andtensilepropertiesofsubmergedarcwelds.Itanalyzesthe effects of different flux compositions on grain structure, phase distribution, and mechanical strength. Results show that flux composition plays a crucial role in determining weld-metal properties by affecting element transfer and microstructuralevolution.Variationsinfluxchemistryimpact tensilestrength,ductility,andoverallweldperformance.The studyhighlightstheimportanceofselectingappropriateflux materialstoachievedesiredmechanicalproperties.Proper flux selection enhances weld quality and ensures better performanceinindustrialapplications.(12)

2.3 EFFECT OF HAZ ON THE QUALITY OF WELD:

C. S.LeeRuhiChandelRuhiChandelH.P.Seow while doing investigatestheeffectofweldingparametersonthesizeof the heat-affected zone (HAZ) in submerged arc welding. It examineskeyfactorssuchasweldingcurrent,voltage,travel speed,andheatinput.Resultsshowthathigherheatinput leads to a larger HAZ, which can affect weld quality and mechanicalproperties.Thestudyhighlightstheimportance of optimizing welding parameters to control HAZ size and minimizeadverseeffects.Properparameterselectionhelps improveweldstrength,toughness,andoverallperformance. Thefindingsprovidevaluableinsightsforachievingbetter weldqualityinindustrialapplications.(13)

AnaMa.Paniagua-Mercado;VctorM.Lpez-Hirata;ArturoF. Mndez-Snchez;MaribelL.Saucedo-Muoz,whileconducting theeffectsofactiveandnonactivefluxesonthemechanical propertiesandmicrostructureofsubmergedarcweldsinA36steelplates.Itanalyzeshowfluxcompositioninfluences weld-metalstrength,toughness,andgrainstructure.Results showthatactivefluxesenhanceelementtransferandrefine microstructure,leadingtoimprovedmechanicalproperties. Incontrast,nonactivefluxesproducecoarsergrainsandmay reduceweldtoughness.Thestudyhighlightstheimportance ofselectingtherightfluxtypetoachievedesiredweldquality. Proper flux selection optimizes weld performance for industrialapplications.(14)

SauravDatta,AsishBandyopadhyayandPradipKumarPal, The study applies the Taguchi method to optimize bead geometryandheat-affectedzone(HAZ)widthinsubmerged arc welding using a mixture of fresh and fused flux. It investigates the effects of welding parameters such as current, voltage, and travel speed on weld quality. Results show that a balanced combination of fresh and fused flux improves bead geometry and minimizes HAZ width. The

studyhighlightstheeffectivenessoftheTaguchiapproachin identifying optimal welding conditions for enhanced performance.Properparameterselectionhelpsimproveweld strength,reducedefects,andensureprocessefficiency.The findingsprovidevaluableinsightsforoptimizingsubmerged arcweldinginindustrialapplications.(15)

Viano, D.M.; Ahmed, N.U.; Schumann, G.O., while doing investigatestheinfluenceofheatinputandtravelspeedon the microstructure and mechanical properties of double tandem submerged arc welded high-strength low-alloy (HSLA)steel.Itexamineshowvariationsintheseparameters affectgrainstructure,hardness,andtensilestrength.Results show that higher heat input leads to coarser grains and reducedstrength,whileoptimizedtravelspeedhelpsrefine themicrostructureandimprovemechanicalproperties.The studyemphasizestheimportanceofbalancingheatinputand travel speed to achieve the desired weld quality. Proper control of these parameters enhances weld toughness, strength, and overall performance. The findings provide valuableinsightsforoptimizingweldingprocessesinHSLA steelapplications.(16)

KeshavPrasad;D.K.Dwivedi,whileconductingexaminesthe microstructure and tensile properties of submerged arc welded 1.25Cr-0.5Mo steel joints. It analyzes how welding parametersinfluencegrainstructure,phasedistribution,and mechanical strength. Results show that the weld metal consists of ferrite and bainite, which affect hardness and tensile properties. Proper control of welding conditions is essentialtoachievingabalancedmicrostructureforoptimal strengthandtoughness.Thestudyhighlightstherelationship between microstructural features and weld performance. Findingsprovidevaluableinsightsforimprovingweldquality in applications requiring high-temperature strength and durability.(17)

3. CONCLUSIONS

The review highlights the critical role of welding parameters, flux composition, and process variations in determining the quality of submerged arc welds. Higher deposition rates can lead to wider and shallower beads, affectingweldpenetrationandstrength.TheuseofmultiplewireSAWandmetalpowderadditionenhancesproductivity while reducing defects. Statistical and numerical optimizationtechniqueshelprefineprocessparametersto achieveimprovedweldquality.Fluxandwirecomposition significantlyinfluencemicrostructure,elementtransfer,and mechanicalproperties.Heatinputandtravelspeedmustbe carefullycontrolledtomaintainthedesiredweldtoughness and microstructural integrity. The study emphasizes the importanceofparameterselectiontominimizedefectsand improveweldconsistency.PropercontrolofHAZwidthand bead geometry enhances mechanical performance and durabilityinweldedjoints.Thesefindingsprovideessential guidance for industrial applications, ensuring better weld

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056

Volume: 12 Issue: 03 | Mar 2025 www.irjet.net p-ISSN: 2395-0072

quality,efficiency,andcost-effectivenessinSAWprocesses. Further research is needed to explore advanced welding techniques and automation to optimize SAW for future applications.

REFERENCES

1) Z.Q. Wanga, “Effect of Ni content on the microstructureandmechanicalpropertiesofweld metal with both-side submerged arc welding technique”,MaterialsCharacterization,138,2018, 67-77.

2) A.V.Patel, “Effect of consumables and heat input Rate on properties of weld in submerged Arc weldingprocess:areview,GISsciencejournal,issn no:1869-9391volume8,issue10,2021pageno: 1057-1064

3) R.S. Chandel, H.P. Seow, F.L. Cheong, “Effect of increasingdepositionrateonthebeadgeometryof submergedarcwelds,”

4) Journal of Materials Processing Technology 72: 124–128(1997).

5) J.Tusek,M.Suban,“High-productivitymultiple-wire submerged-arc welding and cladding with metalpowderaddition,”Journal ofMaterialsProcessing Technology133:207–213(2003)

6) K. Y. Benyounis, A. G. Olabi , “Optimization of different welding processes using statistical and numericalapproaches-Areferenceguide“Volume 39:483-496(2008)

7) Serdar Karaoğlu and Abdullah Seçgin, Sensitivity analysis of submerged arc welding process parameters, Journal of Materials Processing Technology,202:500-507(2008)

8) L.J.Yang,R.S.ChandelandM.J.Bibby,“Theeffectsof processvariablesonthebeadwidthofsubmergedarcwelddeposits,”JournalofMaterialsProcessing Technology,Vol.29:133-144(1992)

9) P. Yongyutph ,K. Ghoshp, C. Guptaa, K. Patwardha And Satya Prakash, “Influence of Macro/Microstructure on the Toughness of'All Weld'MultipassSubmergedArcWeldedC-MnSteel Deposits”ISIJInternational.Vol.32:771-778(1992)

10) N.D. Pandey, A. Bharti and S.R. Gupta, “Effect of submerged arc welding parameters and fluxes on element transfer behavior and weldmetal chemistry”, Journal of Materials Processing Technology,Vol.42:195-211(1994)

11) P.Kanjilal,T.K.PalandS.K.Majumdar,“Combined effectoffluxandweldingparametersonchemical composition and mechanical properties of submerged arc weld metal” Journal of Materials ProcessingTechnology,Vol.171:223-231(2006)

12) De-liangRen,Fu-renXiao,PengTian,XuWangand BoLiao,“Effectsofweldingwirecompositionand welding process on the weld metal toughness of submergedarcweldedpipelinesteel”International

Journal of Minerals, Metallurgy and Materials Vol.16:65-70(2009)

13) AnaMa.Paniagua-Mercado,VictorM.López-Hirata and Maribel L. Saucedo Muñoz, “Influence of the chemicalcompositionoffluxonthemicrostructure and tensile properties of submerged-arc welds” Journal of Materials Processing Technology,Vol. 169:346-351(2005)

14) C. S. LeeRuhi ChandelRuhi ChandelH. P. Seow “EffectofWeldingParametersontheSizeofHeat AffectedZoneof Submerged Arc Welding”August 2000Materials and Manufacturing Processes 15(5):649-666DOI:10.1080/10426910008913011

15) AnaMa.Paniagua-Mercado;VctorM.Lpez-Hirata; ArturoF.Mndez-Snchez;MaribelL.Saucedo-Muoz, “Effect of Active and Nonactive Fluxes on the Mechanical Properties and Microstructure in Submerged-ArcWeldsofA-36SteelPlates”.Journal of materials and manufacturing processesVol.22: 295–297(2007)

16) Saurav Datta, Asish Bandyopadhyay and Pradip KumarPal,“ApplicationofTaguchiphilosophyfor parametricoptimizationofbeadgeometryandHAZ widthinsubmergedarcweldingusingamixtureof freshfluxandfusedflux”TheInternationalJournal ofadvanceManufacturing,Vol.36:689-698(2007)

17) Viano,D.M.;Ahmed,N.U.;Schumann,G.O.,“Influence of heat input and travel speed on microstructure and mechanical properties of double tandem submerged arc high strength low alloy steel weldments,” Journal of science and technology of weldingandjoining,Vol.5:26-34(2000)

18) KeshavPrasad;D.K.Dwivedi,“Microstructureand Tensile Properties of Submerged Arc Welded” 1.25Cr-0.5MoSteelJoints,JournalofMaterialsand Manufacturingprocesses,Vol.23:463-468(2008)

19) BipinKumarSrivastavaetal.“Areviewoneffectof arcweldingparametersonmechanicalbehaviourof ferrous metals/alloys” International Journal of EngineeringScienceandTechnologyVol.2(5),2010, 1425-1432.