Electro Slag Welding Posted Date: 17 Nov 2009     Resource Type: Articles/Knowledge Sharing     Category: Education Author: niranjan Member Level: Gold     Rating: Points: 5

Electro slag welding (ESW): Principle and uses of ESW It is a single pass process using a consumable electrode for filling the gap between two heavy plates. Heat required for melting the work plates and electrodes is obtained initially by an arc. Flux forms in to molten slag or keys extinguish and heat is provided through resistance heating of slag itself. ESW is useful for welding very thick plates and not economical for thinner plates (<50mm). It is used for pressure vessels frames of heavy presses roll mills ship hulls and bogies. ESW setup and operation For a good weld in ESW it is necessary to maintain a continuous slag pool. Hence ESW is done vertically. The slag pool is contained in the grove between work piece with the help of two water cooled copper dam plates or copper shoes which move along with the weld zone. Number of electrodes (filler rods) used depends upon the volume of the weld zone. flux required to maintain satisfactory amount of weld is fairly small (0.2-0.3kg/m of weld length). Hence heat used to melt slag is quite low and most heat goes in to melting the weld joint. Gases present in the weld zone escape through slag. Molten slag also preheats the weld plates about to be welded as the weld pass moves along vertically. The molten base metal and moltened filler metal sink to the bottom between copper dams and molten slag from flux and impurities rises above molten metal. No preparation of surface is needed in ESW as in Resistance welding Electro gas welding (EGW): Electro gas welding (EGW) is similar to ESW but with the addition of some principles of SAW inert gases (CO2 ) provides shielding from oxidation in EGW. In EGW slag provides shielding there is continuous arc in EGW as in SAW but filler rods provide flux in EGW instead of hopper as in SAW.

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