Submerged Arc Welding Calculator
Calculate SAW parameters for high-productivity welding applications.
Wire Diameter vs Current Range
| Wire Dia | Current Range | Voltage Range |
|---|---|---|
| 2.4mm | 200-500A | 24-32V |
| 3.2mm | 300-700A | 26-34V |
| 4.0mm | 400-900A | 28-36V |
| 4.8mm | 500-1100A | 30-40V |
| 5.6mm | 600-1300A | 32-44V |
Submerged Arc Welding Principles
Wire Feed Speed Calculation
WFS (m/min) = Current / (Wire Area x Current Density). For 3.2mm wire at 500A, typical WFS is ~2.5-3.0 m/min.
Voltage Selection
- Lower Voltage: Narrower, more convex bead, deeper penetration
- Higher Voltage: Wider, flatter bead, less penetration, more flux consumption
- Rule of Thumb: Voltage = 0.04 x Current + 16 (for DCEP)
Flux Consumption
- Flux/Wire Ratio: Typically 0.8-1.4 kg flux per kg wire
- Higher Voltage: Increases flux consumption
- Flux Recovery: Unfused flux can be recycled (mix with fresh flux)
- Flux Depth: 25-40mm above arc for proper shielding