This work is an attempt to determine the process variables to achieve the desired weld deposition in a single side single pass submerged arc welding. Prediction of control variables requires a precise analysis of the weld thermal cycle. As the weld nears full penetration, the back surface acts like an insulating barrier and heat flow changes from 3-D toward less efficient 2-D character. Reduced heat transfer means that more melting occurs at the root of the weld than would otherwise occur. Thus large changes in joint penetration occur for subtle changes in process variables. The work presented here considers the modelling of weld metal deposition based on the principals of mass conservation and solution of heat flow equation. The welding parameters are obtained by solving the mass balance and heat conduction equations. A series of experiments has been performed to verify the validity of the model and also to establish the affectivity of the reusable flexible backing strips.
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