Achieving consistent, high-quality results in submerged arc welding requires understanding potential challenges and implementing proven solutions. Leveraging TOKO's specialized welding wires and fluxes:
1Porosity
What it is: The formation of gas pockets or cavities within the weld metal, which severely weakens the joint and can lead to failure.
Primary Causes:
- Damp Flux: This is the most common cause. Moisture in the flux decomposes in the heat of the arc, releasing hydrogen into the weld pool.
- Contaminated Base Metal: Rust, oil, grease, or mill scale on the plate surface.
- Improper Flux Coverage: Inadequate depth of flux blanket allows atmospheric gases to contaminate the weld pool.
How to Avoid it with TOKO:
- Proper Flux Storage & Reconditioning: Always store TOKO fluxes in their original, sealed containers in a dry, temperature-controlled environment. Follow our specific re-baking recommendations if the flux absorbs moisture.
- Meticulous Surface Preparation: Remove all contaminants from the joint area through grinding, brushing, or degreasing.
- Maintain Correct Flux Depth: Ensure a consistent and sufficient layer of flux covers the weld zone, typically between 1 to 1.5 inches deep.
- Use TOKO's Agglomerated Fluxes: Our agglomerated fluxes are designed for low hydrogen levels, making them the ideal choice for welding high-strength, crack-sensitive steels.
2Incomplete Fusion or Penetration
What it is: The weld metal fails to fuse properly with the base metal or the previous weld pass, or it fails to penetrate deeply enough into the joint root.
Primary Causes:
- Incorrect Welding Parameters: Too low amperage, too high travel speed, or improper voltage.
- Faulty Joint Design or Fit-up: Excessively narrow groove angles or large root gaps.
- Incorrect Electrode Positioning: The wire is not aligned correctly with the joint.
How to Avoid it with TOKO:
- Optimize Your Parameters: Refer to TOKO's technical data sheets for our wires and fluxes. Start with our recommended settings for your joint geometry and material thickness.
- Ensure Proper Fit-up: Maintain consistent joint geometry and tight fit-up tolerances before welding.
- Precise Electrode Alignment: Carefully position the electrode to ensure the arc is directed into the deepest part of the joint.
3Weld Cracking (Hot & Cold Cracking)
What it is: Fractures that occur in or near the weld metal. Hot cracking happens while the metal is solidifying, while cold cracking (hydrogen-induced cracking) can occur hours after welding.
Primary Causes:
- High Restraint: The welded parts are unable to move, creating high stress.
- Hydrogen Presence: From damp flux, contaminated surfaces, or moist air.
- Unfavorable Weld Chemistry: A carbon or sulfur content that is too high can promote cracking.
How to Avoid it with TOKO:
- Control Hydrogen at the Source: This is critical. Use low-hydrogen TOKO fluxes and ensure they are dry. Prepare surfaces impeccably.
- Implement Preheating: For thicker materials or high-carbon steels, preheating slows the cooling rate, allowing hydrogen to diffuse away and reducing stress.
- Select the Right Consumables: TOKO offers a range of wire and flux combinations specifically formulated to produce weld metal with optimized chemistry that resists cracking, even under high restraint.
4Undercut
What it is: A groove melted into the base metal at the toe of the weld that is not filled with weld metal. It acts as a stress concentration point.
Primary Causes:
- Excessive Welding Current or Voltage.
- Travel Speed Too High.
- Incorrect Electrode Angle.
How to Avoid it with TOKO:
- Fine-Tune Parameters: Reduce amperage or voltage slightly and avoid excessively high travel speeds.
- Adjust Technique: Ensure the electrode is angled correctly to distribute heat evenly to both sides of the joint.
- Trust TOKO's Arc Stability: Our wires and fluxes are manufactured to provide an exceptionally stable and consistent arc, giving you superior control and minimizing the risk of undercut.
5Irregular Bead Shape & Spatter
What it is: A weld bead that is too convex or uneven, often accompanied by spatter (droplets of expelled metal).
Primary Causes:
- Voltage Too Low: Leads to a high, ropey bead.
- Voltage Too High: Leads to a flat, wide bead and increased spatter.
- Inconsistent Wire Feed Speed or Travel Speed.
How to Avoid it with TOKO:
- Balance Voltage and Amperage: Adjust voltage to achieve a flat, slightly convex bead profile. TOKO's technical support can help you find this "sweet spot."
- Maintain Consistent Speeds: Use reliable, well-maintained equipment to ensure consistent wire feed and travel speed.
- Benefit from Our Formulation: TOKO fluxes are engineered to produce a smooth, aesthetically pleasing bead with minimal spatter, reducing post-weld cleanup time and cost.
TOKO Advantages for Submerged Welding
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Unmatched Consistency: Batch-to-batch uniformity ensures your welding parameters work perfectly every time.
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Optimized Wire & Flux Combinations: We offer perfectly matched sets for specific applications and steel grades.
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Superior Flux Formulations: Our agglomerated fluxes deliver excellent mechanical properties, arc stability, and detachability.
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Expert Technical Support: Our team is ready to help you select the right products and troubleshoot your process.
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Comprehensive Product Range: From basic carbon steel applications to specialized high-strength and stainless steel welding.
Summary
The foundation of successful submerged welding is understanding potential problems and implementing proactive solutions. By combining proper technique with TOKO's high-quality consumables, you can achieve consistent, high-quality welds with minimal defects.
Don't let common welding problems disrupt your productivity and compromise your quality. Contact TOKO Brand today to find the perfect submerged arc welding solution for your project.
Disclaimer: The information contained or otherwise referenced herein is presented only as "typical" without guarantee or warranty,
and TOKO Corporation expressly disclaims any liability incurred from any reliance thereon. Typical data and Test results for mechanical properties,
deposit or electrode composition and other properties were obtained from a weld produced and tested according to prescribed standards, and should not
be assumed to be the expected results in a particular application or weldment. Actual results will vary depending on many factors, including, but not
limited to weld procedure, plate chemistry and temperature, weldment design and fabrication methods. Users are cautioned to confirm by qualification
testing, or other appropriate means, the suitability of any welding consumable and procedure before use in the intended application.
