Submerged arc welding applications normally are limited to flat or horizontal-fillet welding positions and deposition rates can approach 100 lb./hour compared to 10 lb./hour for shielded metal arc welding. Currents ranging from 300-2,000 amps are commonly used. Constant voltage welding power supplies are most commonly used, however constant current systems in combination with a voltage-sensing wire-feeder are available.

Submerged arc welding is a kinder, gentler welding process.

Unlike other welding processes, in submerged arc welding, gravity becomes your friend.

And, because the arc is buried under the flux, it does not produce smoke or fumes, or light or arc flash.

Operators who oversee the submerged arc welding process typically don't have to wear protective clothing, just regular shop clothes.

Said Mike Flagg, manager of the applications engineering department for the Lincoln Electric Company.

Submerged arc welding is software driven, software also can be used to get information out of the process.

The software used in submerged arc welding typically records all parameters on a weld-by-weld basis, and it can be networked so that welding operations can be monitored anywhere in the world.

“It's good for companies with multiple plant locations. They can monitor all plant submerged arc welding operations from one location,” Flagg said.

The submerged arc welding process tends to use larger diameter wires than other processes, typically 1/8 in. or 5/32 in. diameter wires, so high travel speeds and high deposition rates can be attained.

And, it produces extremely high quality welds.

“It's common to run more than one wire into the same puddle. For some longitudinal pipe we'll run up to five wires and get 100 lbs./ hr. deposition rate,” Lincoln Electric's Mike Flagg said.