1. Submerged Arc Welding Submerged Arc Welding
The submerged arc welding process is similar to the gas metal arc welding process except the arc is struck under a blanket of granular flux, hence the name submerged arc welding. The filler metal is a continuously-fed wire electrode like GMAW and FCAW. However, higher deposition rates can be achieved in SAW by using larger diameter electrodes (up to 1/4”) and higher currents ( Amperes). Since the process is almost fully mechanized, several variants of the process can be utilized such as multiple torches and narrow gap welding.

2. SAW Flux / Filler Metal Compositions
F7A2-EM12K
F indicates flux
70-95 ksi UTS, 58 ksi minimum yield strength, 22% elongation
A - as welded; P - postweld heat treated
2 - minimum impact properties of 20 20°F
E indicates electrode (EC - composite electrode)
M - medium manganese per AWS Specifications
% nominal carbon content in electrode
K - produced from a heat of aluminum killed steel
For SAW, The American Welding Society specifies both the flux and the filler metal in a single specification. The “F” part of the specification relates to the flux, and the “E” part to the electrode. Note that an “A” or a “P” is specified to indicate whether the strength is obtained as welded or after a post weld heat treatment.
A typical specification for a flux-filler metal combination is described above. Manganese and carbon content levels are important to specify for hardness and strengths that are required and for resistance of the material to cold cracking

3. Advantages High deposition rates No arc flash or glare
Submerged Arc Welding
High deposition rates
No arc flash or glare
Minimal smoke and fumes
Flux and wire added separately - extra dimension of control
Easily automated
Joints can be prepared with narrow grooves
Can be used to weld carbon steels, low alloy steels, stainless steels, chromium-molybdenum steels, nickel base alloys
SAW has the highest deposition rate of all the deep penetrating arc welding processes making it ideal for thick section and multi-pass welding. Variations of the process can utilize dual arc welding, twin arc welding, multiple torch, and narrow groove welding to increase productivity.
Since the arc is completely submerged in the flux, there is no arc radiation. Screens or light filtering lenses are not needed. Additionally, the smoke and fumes are trapped within the flux and thus minimizing smoke and fumes .
Since the process is simple to mechanize and easily automated, it is extremely consistent once a procedure is qualified. And it can be used on a wide variety of materials.

4. Limitations Flux obstructs view of joint during welding
Submerged Arc Welding
Flux obstructs view of joint during welding
Flux is subject to contamination Þ porosity
Normally not suitable for thin material
Restricted to the flat position for grooves - flat and horizontal for fillets
Slag removal required
Flux handling equipment
There are some limitations with the process, however. The flux which shields the arc and weld pool in SAW also obstructs the operator’s view of the joint and molten weld pool. This makes observation of the pool and joint impossible during welding; thus, correction of problems during welding can be very difficult.
Because of the high current levels common to this process, it is normally not suited for thinner materials.
Due to the presence of a granulated flux, submerged arc welding is limited to the flat and horizontal positions. As with SMAW and FCAW, SAW produces a slag which must be completely removed after each pass.
Finally, additional flux handling equipment is required.