<p dir="ltr" id="isPasted">Since its founding nearly 25 years ago, welding specialist<a href="https://www.elektrolas.com/en/" target="_blank">&nbsp;Elektrolas</a> has evolved from a company that supplies and maintains welding equipment to one that also offers training and quality management services and, most recently, welding automation services. In parallel to this expansion, the Dutch company has also evolved in terms of the technologies it uses. Notably, it has embraced the use of 3D printing (specifically,<a href="https://ultimaker.com/3d-printers/s-series/ultimaker-s5/" target="_blank">&nbsp;UltiMaker’s S5 ProBundle</a>), which has enabled it to improve automated welding setups and streamline operations.</p><h2 dir="ltr">The road to 3D printing adoption</h2><p dir="ltr" id="isPasted">Like many companies familiar with more conventional production techniques, Elektrolas did not immediately recognize the benefits of integrating 3D printing into its processes. It took Thije van Delft, Technical Manager at Elektrolas, to invest in the technology himself and test out how it could be used in a welding context.</p><p dir="ltr">He says: “I had done some tests in school using 3D printers, and I asked the company owner [Joost van den Hooven] if I could buy one. He said it wasn’t possible, so I said ‘I will buy one myself’ and purchased a very simple 3D printer for a couple hundred euros and started with that. We did some tests and after some time, Joost was convinced”. From there, Elektrolas consulted with the engineering students participating in traineeships at the company (who were familiar with 3D printing through their studies) about which 3D printer hardware they should invest in. After much deliberation, UltiMaker’s S5 ProBundle was chosen.</p><h2 dir="ltr">Unlocking new applications</h2><p dir="ltr">The UltiMaker 3D printer has played an important role at the company, particularly as Elektrolas has ramped up its automation department (spearheaded by van Delft), supplying robotic and cobot welding systems to customers in the Netherlands and beyond. To date, the company has sold and installed dozens of cobot welding systems, which empower its customers to accelerate their lead times and achieve consistent quality, all while mitigating labor shortages in the welding sector.</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyMjMzMTE3NjI2LWluc2lkZXdlbGQuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Thije van Delft with the UltiMaker S5 ProBundle, and the cobot welding rig in the back.</span></span></span></p><p dir="ltr" id="isPasted">3D printing has come into play in the production of clamps, which are installed on welding cobots to keep things running smoothly and to ensure the freedom of movement of the robotic arm. Van Delft explains: “We have a holder and an arm clamp that attach the torch hose to the robot. This is made up of two parts: one part that clamps to the robot and one part that attaches to the hose. These are fixed with a fixing pin. If you wanted to make that using milling or other conventional processes, it would not be possible.”</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyMjM2NzgwMjQ1LWxvdyBpbm5lci5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">The complex form of the clamp makes it perfect to be 3D printed at a cost and timeframe impossible to replicate in other manufacturing methods. Image credit: Elektrolas.</span></span></span></p><p dir="ltr" id="isPasted">The company has also found it possible to quickly iterate replacement parts for the 3D printed clamps. Made from Tough PLA, it does happen that the clamps break sometimes. “In this case it’s very easy to print a new one and send it the next day to the customer,” van Delft says. “The customer simply sends a picture of what part is broken, we start the printer, and the next day we can send it via DHL to the customer.” This, of course, has the obvious benefit of eliminating the need for large inventories of spare clamps, since they can be printed on demand.</p><p dir="ltr" id="isPasted">Elektrolas has also turned to 3D printing in the production of temporary holders that attach hand welding torches to robotic or cobot systems. In this case, UltiMaker’s solution enabled Elektrolas to meet the needs of one of its customers who wanted to integrate a manual welding torch in an automated system. “We called the supplier of this welding torch, but the automatic version had a delivery time of 10-12 weeks,” van Delft recalls. By designing and 3D printing a holder to attach the welding torch to the robot, Elektrolas was able to offer its customer a stopgap solution while they waited for the final part from the welding torch supplier. This enabled them to keep their automated welding production up and running rather than being setback by system downtimes.</p><h2 dir="ltr">Why the UltiMaker’s S5 ProBundle?</h2><p dir="ltr">While both UltiMaker and Elektrolas are based out of the Netherlands, the local appeal was only part of the equation when the welding company started looking for a 3D printing solution to adopt three years ago. UltiMaker’s S5 ProBundle is a professional-grade solution that combines UltiMaker’s reliable dual-extrusion technology with advanced features like automated material management, superior air filtration, and humidity control for filament. The 3D printer also has a sizable print volume (330 x 240 x 300 mm), which was an important factor for Elektrolas as the company often prints large components.</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyMjM2ODQ0NTY0LWRlZXAgLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Multiple prints can be completed simultaneously in the S5’s large print bed.&nbsp;</span></span></span></p><p dir="ltr" id="isPasted">Ease of use and print quality were also top of mind for van Delft and his team. The UltiMaker S5 ProBundle delivered on both fronts. Elektrolas has achieved consistency from print to print thanks to the ability to save setup and print settings in Cura. As van Delft explains, he and his team are able to design the parts they need in SolidWorks and print them on demand with the touch of a button. This is also thanks to the work of their trainee students, who have pre-programmed print settings, and UltiMaker’s intuitive user interface, which enables one-button printing. “If, for example, a client wants to weld with some special machine but there is no welding torch on the robot, we can take a normal welding torch and sketch a holder in SolidWorks and then print it.” Using this approach, test parts can be delivered the next day.</p><p dir="ltr">In terms of printing materials, Elektrolas is primarily working with<a href="https://ultimaker.com/materials/s-series-tough-pla/" target="_blank">&nbsp;UltiMaker Tough PLA</a>, a technical PLA filament that offers good toughness (similar to ABS), as well as minimal warping and excellent printability at an affordable cost. While not the most robust material in UltiMaker’s portfolio, Tough PLA does meet the needs of the welding company for the clamps and holders. Even the material’s weaknesses have proven to be a benefit. “I have twice received a request for a new 3D printed clamp because the operator of the robot made a mistake and broke the clamp when the torch hit some corner when the robot was moving,” van Delft elaborates. “Here it is good that the clamp breaks, because it protects the torch from breaking. The clamp is not expensive and easy to replace, the torch is not.”</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyMjM2OTA5Mjg1LWxvdyByZXMuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">The 3D printed clamps enable the welding hoses to be safely secured. By printing in Tough PLA, the clamps are robust but also quick and affordable to replace when needed.</span></span></span></p><p dir="ltr" id="isPasted">Elektrolas also benefits from other features that come with the S5 ProBundle, including Air Manager, an enclosure that provides closed inside-out airflow and filters up to 95% of ultrafine particles (UFPs) generated in the printing process, and the S5 Material Station. This piece of equipment stores and protects up to six spools of filament and offers end-of-filament detection and automatic spool switching, which facilitates lights-out printing. “If you have a big print, it is maybe 35-45 hours of printing,” van Delft adds. “Since we have big prints, the material station can change the PLA by itself and keep the print going until it’s ready the next day.”</p><p dir="ltr">For 3D printer maintenance and technical support, Elektrolas turns to <a href="https://www.makerpoint.nl/nl-nl/" target="_blank">MakerPoint</a>, a Dutch supplier of 3D printing systems and maintenance provider based in Arnhem, Best, and Harlingen.</p><h2 dir="ltr">Intuitive 3D printing for traditional manufacturing</h2><p dir="ltr">Elektrolas is one of many businesses in the traditional manufacturing sphere that has reaped the benefits of UltiMaker’s professional 3D printing solutions. For example,<a href="https://www.wevolver.com/article/eriks-leveraging-3d-printing-to-improve-manufacturing-processes" target="_blank">&nbsp;industrial supplier ERIKS BV</a> relies on UltiMaker systems for a range of applications, including prototyping, tooling, customized jigs and fixtures, and replacement parts. You can find more<a href="https://www.wevolver.com/profile/team.ultimaker" target="_blank">&nbsp;UltiMaker client stories here</a>.</p>

Dutch welding solutions specialist Elektrolas uses the UltiMaker 
S5 ProBundle to minimize machine downtimes and facilitate cobot welding for its customers.


How UltiMaker 3D Printing Supports Automated Welding

<p>In order to get the most out of your 3D printer, you need to align the material you are using with the requirements of your application. This is especially true when creating high-performance parts such as those enabled by carbon fiber. In this post, we will be zooming in on the practical applications of 3D printed carbon fiber composites across multiple categories in order to explore how this unique material is driving efficiency and precision in everything from welding to robotic automation.</p><p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe width="640" height="360" src="https://www.youtube.com/embed/mf0I5aXjr08?&wmode=opaque&rel=0&enablejsapi=1&origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe></span></p><h2 id="isPasted">Carbon fiber composite 3D printing in action</h2><p>The following are four example applications that are well served by the unique properties that carbon fiber offers:</p><h3>Enhancing Welding Processes with Custom Fixtures</h3><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1692016897308-Enhancing-Welding-Processes-with-Custom-Fixtures-UltiMaker-3D-printing.jpg" style="width: 766px;" class="fr-fic fr-dib"></p><p id="isPasted">In the realm of welding, precision and accuracy are paramount. Custom fixtures, specifically designed to hold the pieces together before the welding process, play a crucial role. These fixtures need to be sturdy and heat-resistant, given the high temperatures involved in welding.</p><p>One of&nbsp;<a href="https://ultimaker.com/learn/the-advantages-of-3d-printing-with-carbon-fiber/" target="_blank">the advantages of 3D printing with carbon fiber</a> is that it&rsquo;s possible to create custom fixtures that meet these stringent requirements. The high heat deflection temperature and rigidity of the new UltiMaker PET CF after annealing, in particular, makes it perfect for the task. The ability to design these fixtures in CAD and print them directly reduces labor time and ensures a tight tolerance fit, improving the overall efficiency and quality of the welding process.</p><h3>Bending Dies for Versatile Metal Shaping</h3><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1692016916593-Bending-Dies-for-Versatile-Metal-Shaping-UltiMaker-3D-printing.jpg" style="width: 766px;" class="fr-fic fr-dib"></p><p id="isPasted">Bending dies are crucial tools used with a hydraulic press to shape and form metal parts. Depending on the job specifics or facility requirements, these parts may need frequent customization. Traditional manufacturing methods can be time-consuming and costly for such instances.</p><p>With 3D printing technology, you can create custom bending dies quickly and efficiently. Carbon fiber composites stand out as the material of choice here, thanks to their exceptional rigidity. This means the part can hold its form under more pressure than many other polymers, ensuring the die maintains the intended shape and produces accurate, high-quality metal parts.</p><h3>Robotic Automation with End-of-arm Tooling</h3><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1692016937822-Robotic-Automation-with-End-of-arm-Tooling-UltiMaker-3D-printing.jpg" style="width: 766px;" class="fr-fic fr-dib"></p><p id="isPasted">In the field of manufacturing automation, robotic arms are invaluable tools for performing repetitive tasks with exceptional precision. The tools at the end of these arms, known as end effectors, can vary greatly depending on the specific application, from gripping devices to welding torches.</p><p>The ability to 3D print these end effectors with carbon fiber composites presents a game-changing opportunity. The lightweight nature of carbon fiber composite reduces the overall weight of the robotic arm, increasing its payload capacity, speed, and maneuverability. This not only enhances productivity but also extends the lifespan of the robotic arm by reducing wear and tear.</p><h3>Ensuring Precision with Alignment Tools</h3><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1692016963917-Ensuring-Precision-with-Alignment-Tools-UltiMaker-3D-printing.jpg" style="width: 766px;" class="fr-fic fr-dib"></p><p id="isPasted">Alignment tools or gauges are used in manufacturing and assembly processes for quick and precise measurements. These tools need to be rigid to ensure they don&rsquo;t flex or compress during measurements, which could lead to inaccuracies and inconsistent assemblies.</p><p>Carbon fiber composites, with their inherent rigidity, make an excellent choice for these tools. The ability to 3D print these tools means you can customize them for any specific measurement requirement, ensuring your manufacturing process is as accurate and efficient as possible.</p>

In this post, we will be zooming in on the practical applications of 3D printed carbon fiber composites across multiple categories in order to explore how this unique material is driving efficiency and precision in everything from welding to robotic automation.

Finding the perfect carbon fiber 3D printing application

<h2 id="isPasted">What Is Plasma Welding?</h2><p>Plasma arc welding (PAW) is a fusion welding process that uses a non-consumable electrode and an electric plasma arc to weld metals. Similarly to TIG, the electrode is generally made out of thoriated tungsten.<strong>&nbsp;Its unique torch design produces a more focused beam than TIG welding</strong>, making it a great choice for welding both thin metals and creating deep narrow welds.</p><p>Plasma welding is often used to <a href="https://fractory.com/stainless-steel-welding-explained/" target="_blank">weld stainless steel</a>, aluminum, and other difficult metals compared to traditional methods. Similarly to <a href="https://fractory.com/gas-welding-explained/" target="_blank">oxy-fuel welding</a>, this process can also cut metal (<a href="https://fractory.com/plasma-cutting/" target="_blank">plasma cutting</a>), making it a versatile tool for fabricators and manufacturers.</p><h2>Plasma Arc Welding Process</h2><p><span class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable" contenteditable="false" draggable="true"><iframe width="640" height="360" src="https://www.youtube.com/embed/588EJInHLsc?&wmode=opaque&rel=0&enablejsapi=1&origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe></span></p><p id="isPasted">The plasma arc welding process revolves around the principle of striking an arc between a non-consumable tungsten electrode and the workpiece. The plasma nozzle has a unique design feature, where the electrode is located within the body of the torch. <strong>This allows the arc plasma to exit the torch separated from the shielding gas envelope.</strong></p><p>Additionally, the narrow opening of the nozzle increases the plasma gas flow rate, allowing for deeper penetration. While filler metal is typically supplied at the weld pool&rsquo;s leading edge, it is not the case when creating root pass welds.</p><p>The complexity of the plasma welding torch sets it apart from gas tungsten arc welding. <strong>Plasma welding torches operate at very high temperatures</strong>, which can melt away their nozzle, making it a requirement to always be water-cooled. While these torches can be manually operated, nowadays, <strong>most modern plasma welding guns are designed for automatic welding</strong>.</p><p>The most <a href="https://fractory.com/welding-defects-types-causes-prevention/" target="_blank">common defects</a> associated with plasma welding are tungsten inclusions and undercutting. Tungsten inclusions occur when the welding current exceeds the capabilities of the tungsten electrode and small droplets of tungsten get entrapped in the weld metal. Undercuts are generally associated with keyhole mode PAW welding and can be avoided by using <a href="https://weldknowledge.com/2015/10/03/plasma-arc-welding-paw-with-activated-flux/" rel="noopener" target="_blank">activated fluxes</a>.</p><h3>Plasma Arc Welding Operating Modes</h3><p>Three operating modes are used in plasma welding, wherein it can be operated at varying currents:</p><h4>Microplasma (0.1 &ndash; 15A)</h4><p>This operating mode can run arcs at low currents and remain stable up to 20mm arc length.</p><p>Microplasma welding is used to join thin sheets up to 0.1 mm in thickness, which is optimal for creating wire meshes with minimal distortion.</p><h4>Medium current (15 &ndash; 200A)</h4><p>The characteristics of the plasma arc are quite similar to TIG welding, but the arc is stiffer since the narrow opening of the torch restricts the plasma. We can increase weld pool penetration by speeding up the plasma flow rate, but this increases the risk of shielding gas contamination.</p><p>Medium current or melt-in mode offers better penetration than TIG and improved protection. The only drawback is that the torch requires maintenance and is bulkier compared to a TIG torch.</p><h4>Keyhole mode (over 100A)</h4><p>A powerful plasma beam is used to engage in high-current aka keyhole mode by increasing the gas flow and welding current. This mode allows deep penetration, using a single pass (up to 10mm thick for some materials) to create a consistent weld pool from molten metal.</p><p>Similarly to <a href="https://fractory.com/electron-beam-welding-ebw-explained/" target="_blank">electron beam welding</a>, the keyhole mode is great for welding thicker materials at high welding speeds. To guarantee satisfactory welds, filler material is generally added. Its welding applications include mechanised welding, positional welding, and pipe welding.</p><h3>Comparison of Plasma and TIG Welding</h3><p>Normally, a tungsten electrode is used in TIG welding to strike an arc between the torch and the workpiece. The plasma process works similarly but uses a different setup in its welding torch. The constricted nozzle design allows electrons to move at high velocities. This ionises the gas, creating a plasma jet with a high heat concentration, offering deeper penetration.</p><p>As plasma welding offers greater precision than TIG welding, it has a smaller <a href="https://fractory.com/heat-affected-zone-causes-effects-reduction/" target="_blank">heat-affected zone</a> which is perfect for creating narrower welds. Ideally, plasma welding is a better choice than TIG welding, as it is an evolution of the latter. The technology behind its equipment allows it to run with lower current demand, better arc stability which leads to better stand-off distance, and better <a href="https://fractory.com/engineering-tolerances/" target="_blank">tolerances</a> if the arc length is changed.</p><p>TIG welding however is a simpler method due to the complex parameters available for plasma gas welding. An operator would need extra training in order to transition from the already advanced TIG welding to PAW. And last, TIG welding equipment is cheaper and requires less maintenance than plasma arc welding&rsquo;s sensitive and complex torch.</p><h3 id="isPasted">Materials</h3><p>Similarly to TIG welding, plasma welding is suitable for the majority of well-known metals, although it might not be the most <a href="https://fractory.com/design-to-cost-dtc/" target="_blank">cost-effective</a> solution for some of them:</p><ul><li><p>Alloy Steel</p></li><li><p><a href="https://fractory.com/aluminium-grades/" target="_blank">Aluminium</a></p></li><li><p>Bronze</p></li><li><p>Carbon Steel</p></li><li><p>Copper</p></li><li><p>Iron</p></li><li><p>Inconel</p></li><li><p>Lead</p></li><li><p>Magnesium</p></li><li><p>Monel</p></li><li><p>Nickel</p></li><li><p><a href="https://fractory.com/what-is-stainless-steel/" target="_blank">Stainless Steel</a></p></li><li><p>Titanium</p></li><li><p>Tool Steel</p></li><li><p>Tungsten</p></li></ul><h3>Equipment</h3><p>The key components of plasma welding equipment are:</p><h4>Plasma torch</h4><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1689323314641-plasma-welding-torch.jpg.jfif" style="width: 768px;" class="fr-fic fr-dib"><span class="fr-inner"></span></span></span></p><figure id="isPasted"><figcaption>Plasma torch &ndash; plasma gas is separated from the shielding gas envelope.</figcaption></figure><p></p><figure id="isPasted"><figcaption><br></figcaption></figure><p><span style="background-color: transparent;">The unique design of the water-cooled plasma torch is the main distinguishing factor from other welding processes. Its operating principles have already been explained in previous sections.</span></p><p>Depending on the weld material and desired weld characteristics, different types of nozzle tips can be selected.</p><h4>Control console</h4><p>While conventional welding techniques directly connect a torch to a power source, plasma arc welding uses a control console between the two.</p><p>Some of the console features are the torch protection circuit, high-frequency arc starting unit, power supply for the pilot arc, water, and gas valves, individual meters for plasma, and shielding gas flows.</p><h4>Power supply</h4><p>Plasma arc welding uses DC power (rectifiers or generators) of at least 70 volts for open circuit voltage with drooping characteristics to have greater control in generating weld beads.</p><h4>Gases used</h4><ul><li><p>Plasma gas &ndash; exits the constricting nozzle separately from the shielding gas envelope and becomes ionised</p></li><li><p>Shielding gases (argon, helium, hydrogen) &ndash; inert gas protects the weld from the atmosphere</p></li><li><p>Back-purge and trailing gas &ndash; certain materials require special conditions</p></li></ul><h4>Wire feeder</h4><p>Plasma welding may use wire feeders with a constant velocity that can be modified to run from 254 mm per minute to 3180 mm per minute.</p><h3>Applications</h3><h4>Steel tubes</h4><p>PAW is a great welding method in manufacturing steel tubes as it can be performed at high-speed welding with great metal penetration. Some industries prefer the plasma welding process to conventional TIG since its system is faster and uses less filler material.</p><h4>Electronics</h4><p>One of the welding parameters of the plasma welding process is it can run at low current modes. This mode allows small metal component welding, which deals with delicate materials sensitive to environmental factors.</p><h4>Medical industry</h4><p>Medical devices require precise components in order to run effectively. PAW is perfect for welding these components as it can reliably create a consistent weld bead.</p><h2>Advantages of Plasma Welding</h2><ol><li><p>Can be operated in every welding position.</p></li><li><p>Fast travel speeds from concentrated heat input.</p></li><li><p>Keyhole welding allows for complete penetration.</p></li><li><p>Low current mode is suitable for thin and sensitive components.</p></li></ol><h2>Disadvantages of Plasma Welding</h2><ol><li><p>Expensive equipment and components.</p></li><li><p>Requires training and skill to create good welds.</p></li><li><p>Produces 100dB noise.</p></li><li><p>Creates ultraviolet and infrared radiation.</p></li><li><p>Water cooling is necessary because of high working temperatures.</p></li><li><p>Delicate equipment needs a higher amount of maintenance.</p></li></ol>

Plasma welding is an arc welding process that uses a plasma torch to join metals. The principle of this method is derived from GTAW aka TIG welding, where an electric arc is struck between the electrode and the workpiece.

Let’s dig deeper and explore what plasma welding is all about.

Plasma Arc Welding (PAW) Explained

<p data-pm-slice="1 3 []" id="isPasted">Submerged arc welding is a standard industrial process wherein an arc is formed between a workpiece and an electrode. It was invented in 1935 by the E. O. Paton Electric Welding Institute in Kyiv, Ukraine as a driving force behind the Second World War. One of the most notable applications of this invention is the&nbsp;<a href="https://en.wikipedia.org/wiki/T-34" rel="noopener" target="_blank">T34 military tank</a>.</p><p>While this <a href="https://fractory.com/types-of-welding-processes/" target="_blank">welding technology</a> has been around for almost a century, it is still an essential choice for many industries.</p><h2 id="isPasted">What Is Submerged Arc Welding?</h2><p>Submerged arc welding (SAW) is a welding method where similarly to other arc welding processes, the base metals are joined by forming an electric arc between the workpiece and an electrode.</p><p>SAW process&rsquo;s defining element is how it protects the weld metal from atmospheric contamination.&nbsp;<strong>Submerged arc welding uses a powdered flux layer, generating shielding and slag while creating a smooth and clean weld.</strong> Other methods use shielding gas (<a href="https://fractory.com/mig-vs-tig-welding/" target="_blank">MIG/TIG welding</a>), flux-cored wire (<a href="https://fractory.com/flux-cored-arc-welding-explained/" target="_blank">FCAW</a>), flux-coated electrode (<a href="https://fractory.com/shielded-metal-arc-welding/" target="_blank">SMAW</a>), or controlled environment (<a href="https://fractory.com/plasma-arc-welding-paw-explained/" target="_blank">plasma welding</a>) for protecting the weld.</p><h2>How Does the Submerged Arc Welding Process Work?</h2><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjg4MDM3NDg5NTYwLXN1Yi1hcmMtd2VsZGluZy1lcXVpcG1lbnQtNC5qcGcuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 766px;" class="fr-fic fr-dib"></p><p id="isPasted">Submerged arc welding creates consistent welds by using a blanket of granulated flux. For this reason,&nbsp;<strong>the process can be operated only on positions that are flat and horizontal</strong>, with the weld advancing by either moving the welding system or the workpiece.</p><p>Flux is fed into the joint manually or by using a flux hopper. A single electrode or multiple wire electrode system is placed into the working area, surrounded by the flux blanket. Parameters such as the welding current, arc voltage, and wire feed speed are set depending on the&nbsp;<a href="https://fractory.com/types-of-metal/" target="_blank">type of metal</a>, its thickness, and desired&nbsp;<a href="https://fractory.com/mechanical-properties-of-materials/" target="_blank">mechanical properties</a>. Electric current is supplied to the electrodes, producing intense heat that melts and fuses the base material and the filler wire to the bead.</p><p>The molten metal cools down, creating strong uniform welds and reusable granular flux at the surface and slag underneath. A hopper collects the reusable flux, while slag is usually peeled off manually.</p><p>SAW produces high-quality welds with fewer&nbsp;<a href="https://fractory.com/welding-defects-types-causes-prevention/" target="_blank">weld defects</a> than other processes. However, this does not mean that defects won&rsquo;t ever occur. When they do, it&rsquo;s generally related to wrongly set welding parameters.</p><h2>Flux</h2><h3>Granular Flux</h3><p>Granular flux inside a hopper is usually composed of oxides from aluminium, calcium, magnesium, manganese, silicon, titanium, and zirconium. This composition suits the type of electrode to achieve the metal&rsquo;s desired properties as it chemically reacts as it melts.</p><h3>Bonded Flux</h3><p>Bonded flux is produced by drying the composition and slowly baking it, usually with a compound such as sodium silicate. As an advantage, bonded flux can contain alloying elements, offering flexibility for some applications and protection against rust.</p><h3>Fused Flux</h3><p>Fused flux is produced by melting the composition inside an electric furnace. The molten flux is formed into homogenous particles as it solidifies. It is excellent for creating consistent welds along the bead.</p><h2>Wire Electrode</h2><p>SAW uses a wire spool to feed the wire electrode into the weld.&nbsp;<strong>The wire&rsquo;s thickness is usually between 1.6mm and 6mm</strong>. Electrodes may come in the form of solid, twisted, or cored wire and may be operated using different power sources.</p><p>Specific circumstances may need the use of modified wire electrodes and electrode systems to achieve the desired weld profile:</p><ul><li><p>Twin-wire</p></li><li><p>Multiple wires</p></li><li><p>Single wire with hot/cold addition</p></li><li><p>Metal powder additive</p></li><li><p>Tubular wire</p></li></ul><p>Multiple wire systems typically use a lead wire to improve penetration, while a trailing wire is used to add extra fill and improve the bead profile. Additional wires are used in the electrode system to add more deposition to the weld pool.</p><h2 id="isPasted">Materials</h2><p>Submerged arc welding process is used with the following materials:</p><ul><li><p>Copper alloys</p></li><li><p>Low to medium-carbon steels</p></li><li><p>Low-alloy steels</p></li><li><p>Mild steels</p></li><li><p>Nickel-based alloys</p></li><li><p><a href="https://fractory.com/quenching-explained/" target="_blank">Quenched</a> and&nbsp;<a href="https://fractory.com/tempering-explained/" target="_blank">tempered steel</a></p></li><li><p>Stainless steels</p></li><li><p>Uranium alloys</p></li></ul><h2>Power Source</h2><p>Submerged arc welding can operate on multiple power outputs, allowing it to manipulate the weld results. Multiple electrode systems enable SAW to run wires at different power sources, to better control the bead profile and penetration.</p><p>DCEP offers the most stability and penetration, while DCEN is optimal in increasing deposition rates. Running this welding process in AC is the middle ground where a balance between the two is achieved.</p><h2>Applications and Industries</h2><p><span class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable" contenteditable="false" draggable="true"><iframe width="640" height="360" src="https://www.youtube.com/embed/NrGzYK-H5oI?&wmode=opaque&rel=0&enablejsapi=1&origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true" data-gtm-yt-inspected-9="true" id="978819855" title="SUBMERGED ARC WELDING MACHINE"></iframe></span></p><h3 id="isPasted">Fabrication</h3><p>SAW is one of the preferred welding processes in fabricating pressure vessels, pipes, and boilers due to its strength in longitudinal and circumferential welding. This welding operation achieves a smooth weld pool from the continuously fed electrode.</p><h3>Shipbuilding</h3><p>The flexibility of SAW process allows it to be performed both indoors and outdoors which makes it suitable for shipbuilding. It&rsquo;s perfect for creating long, straight welds for heavy metals which make up ship parts.</p><h3>Automotive</h3><p>Metals used in the automotive and military industry are fit for SAW, along with the speed and efficiency it brings. This welding method is also perfect for automation, with the option to have multiple or single-pass welds based on the metal&rsquo;s thickness.</p><h3>Railways</h3><p>The submerged arc process allows deep weld penetration, which is attractive to the railway industry.</p><h2>Advantages of SAW</h2><ol><li><p>The blanket of granular flux creates minimal welding fume and spatter.</p></li><li><p>Allows performing semiautomatic or fully automatic welding.</p></li><li><p>Flexible for both indoor and outdoor applications.</p></li><li><p>Creates smooth, uniform and deep welds.</p></li><li><p>Around 50-90% of the flux is reusable and recyclable.</p></li></ol><h2>Limitations of SAW</h2><ol><li><p>Limited to flat and horizontal welding positions</p></li><li><p>A rather narrow range of weldable metals.</p></li><li><p>Requires post-welding slag removal.</p></li><li><p>Practically restricted to circumferential and long straight beads.</p></li><li><p>Precise parameters are required to achieve desired weld deposit since welds aren&rsquo;t visible while welding.</p></li></ol>

Submerged arc welding is a standard industrial process wherein an arc is formed between a workpiece and an electrode. It was invented in 1935 by the E. O. Paton Electric Welding Institute in Kyiv, Ukraine as a driving force behind the Second World War. One of the most notable applications of this invention is the T34 military tank.