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Electro Slag Welding

Electro Slag Welding (ESW) is a high-deposition welding process designed for joining thick metal plates in a vertical position using electrical resistance as the primary heat source. The process involves several steps, including joint preparation, arc initiation, and solidification, with advantages such as high deposition rates and low distortion, but also drawbacks like coarse grain structure and limited to vertical applications. ESW is primarily used for welding steel and involves the formation of a molten slag pool that facilitates the welding process.

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Mech Akash Kumar
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51 views2 pages

Electro Slag Welding

Electro Slag Welding (ESW) is a high-deposition welding process designed for joining thick metal plates in a vertical position using electrical resistance as the primary heat source. The process involves several steps, including joint preparation, arc initiation, and solidification, with advantages such as high deposition rates and low distortion, but also drawbacks like coarse grain structure and limited to vertical applications. ESW is primarily used for welding steel and involves the formation of a molten slag pool that facilitates the welding process.

Uploaded by

Mech Akash Kumar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd

Electro Slag Welding (ESW) is a high-deposition welding process used to join very thick

metal plates (typically 25 mm to 300 mm) in a vertical position in a single pass.

Unlike conventional arc welding, the main heat source in ESW is electrical resistance, not
an electric arc. The arc is only used to start the process; once running, the current passes
through a conductive molten slag which generates heat (Joule heating) to melt the filler wire
and base metal.

Diagram of the Process

The diagram above typically illustrates:

 Vertical Plates: The workpieces being joined.


 Water-Cooled Copper Shoes: Dampers on both sides to contain the molten metal.
 Molten Slag Pool: The resistive heating element floating on top.
 Molten Weld Pool: The liquid metal beneath the slag.
 Solidified Weld Metal: The finished joint cooling at the bottom.
 Wire Guide/Electrode: Feeding into the slag bath.

Step-by-Step Explanation

Step 1: Joint Setup & Preparation

Step 2: Arc Initiation (The Start)

Step 3: Slag Bath Formation

Step 4: Resistance Heating (The Steady State)

Step 5: Coalescence and Rise

Step 6: Solidification & Cooling

Step 7: Completion

Electroslag Welding is a welding process, in which the heat is generated by an electric


current passing between the consumable electrode (filler metal) and the work piece
through a molten slag covering the weld surface.

Prior to welding the gap between the two work pieces is filled with a welding flux.
Electroslag Welding is initiated by an arc between the electrode and the work piece (or
starting plate). Heat, generated by the arc, melts the fluxing powder and forms molten
slag. The slag, having low electric conductivity, is maintained in liquid state due to heat
produced by the electric current.

The slag reaches a temperature of about 3500°F (1930°C). This temperature is sufficient
for melting the consumable electrode and work piece edges. Metal droplets fall to the
weld pool and join the work pieces.

Electroslag Welding is used mainly for steels.


Advantages of Electroslag Welding:
 High deposition rate - up to 45 lbs/h (20 kg/h);
 Low slag consumption (about 5% of the deposited metal weight);
 Low distortion;
 Unlimited thickness of work piece.
Disadvantages of Electroslag welding:
 Coarse grain structure of the weld;
 Low toughness of the weld;
 Only vertical position is possible.

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