Abstract— Welding is a process of permanent joining of two metals through localized coalescence resulting from a suitable combination of temperature, pressure and metallurgical conditions. Depending upon the combinations of the above mentioned, a wide range of welding processes has been developed. Submerged Arc Welding (SAW) is an automatic welding process and is one of the chief metal fabrication process in industries, which involves high current density and effects high metal deposition rates. In SAW, the process parameters like welding current, arc voltage, speed of arc travel, size of electrode, electrode stick-out, heat input rate are to be studied. To get an optimum result, one must know their effects and how to select and control them. The present work is carried out to study the influence imposed by electrode extension, one of the important process parameters of SAW on a major welding defect known as distortion on a commercial use mild steel plate of size 150mm x 200mm x 10mm. The direct interaction effects of electrode stick-out on welding distortion is brought and concluded by graphical plots.

Index Terms— Submerged Arc Welding, Electrode, Flux, Arc, Slag, Distortion

Cite: B E Mallikarjuna, Yellappa M, Satyamurthy N, Giriswamy B G, and Puneet U, " Studies on the Effect of Electrode Extension and Process Parameters on Distortion by Submerged Arc Welding," International Journal of Mechanical Engineering and Robotics Research, Vol. 3, No. 2, pp. 333-339, April 2014.