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Submerged Arc Accessories

Frequently Asked Questions

What accessories are essential to set up a submerged arc welding (SAW) system?
A complete SAW setup requires a contact nozzle assembly, flux hopper and delivery hose, flux recovery/recirculation system, and a travel carriage or tractor. Lincoln Electric's PIM catalog lists contact nozzle assemblies including the K231-1 (600A) and K231-2 (1200A HD), along with nozzle extensions like the KP1975-2 and curved 45° extensions (KP2721-2) for reaching offset joint configurations. The MAXsa 19 MSA controller (K3172-1) is used with automated SAW systems to manage wire feed and travel speed.
How do I choose the right contact nozzle for my SAW application?
Contact nozzle selection depends primarily on wire diameter and amperage. The standard 600A nozzle assemblies (K231-1, K148A, K148B) handle typical production SAW at wire sizes up to 3/32 in. (2.4 mm). For high-current multi-wire or tandem arc setups, the 1200A HD nozzle assembly (K231-2) is required. Always match the nozzle bore to your wire diameter — an oversized bore causes poor electrical contact and arc instability.
What is a Twinarc kit and when would I use one?
Lincoln's Twinarc kit (K225) feeds two wires through a single contact nozzle, creating a larger weld pool and significantly higher deposition rates than single-wire SAW. Twinarc is used in high-production structural steel fabrication, heavy plate welding, and pipe mill applications where maximum deposition rate and heat input are acceptable. It requires a power source capable of handling the combined current load.
How is unfused SAW flux recovered and reused?
In automated SAW systems, a flux recovery unit (vacuum or pneumatic) picks up the unfused flux behind the weld head, screens out slag and oversized particles, and returns clean flux to the hopper. AWS guidance specifies removing fused slag, small fines, and oversized material during recovery so only properly graded flux is recirculated. Recycled flux should be periodically blended with virgin flux to maintain consistent chemistry and moisture content, which affects weld metal mechanical properties.
Can I use SAW accessories from other manufacturers with my Lincoln wire feeder?
Contact nozzles, nozzle extensions, and flux delivery components are often proprietary to the wire feeder or gun model. Lincoln accessories designed for the NA-3, NA-4, or MAXsa series feeders may not fit competing gun heads without an adapter. Using mismatched components risks poor electrical contact, flux delivery problems, and premature wear. Stick with Lincoln-matched accessories when possible to maintain the warranted performance of your system.
How often should SAW contact nozzles be inspected or replaced?
Contact nozzles wear through a combination of arc erosion and abrasion from the wire electrode. Inspect the bore daily for ovality, enlargement, or pitting. A worn nozzle bore that is more than 50% larger than nominal wire diameter should be replaced — it will cause erratic current transfer, arc wander, and inconsistent bead profile. In continuous production, many shops establish a scheduled replacement interval (e.g., every 8–16 hours of arc time) to prevent unplanned downtime.