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Application status and development trend of narrow gap welding
Narrow gap welding technology, first introduced in the *Iron Age* magazine in December 1963 by the American Battelle Institute, marked a significant advancement in the field of welding. Although the term "narrow gap welding" was later officially used in the *British Welding Journal* in May 1966, the concept had already begun to attract global attention. This technique quickly became a focal point for researchers due to its potential to improve efficiency and reduce material usage in thick-section welding. Scholars like VY Marin have highlighted key characteristics of narrow gap welding, such as the use of existing arc welding techniques, I-shaped grooves with specific angles, multi-layer welding, controlled weld numbers, low heat input, and all-position welding capabilities.
The Japan Pressure Vessel Committee's Eighth Special Committee later defined narrow gap welding as a method involving steel plates of 30 mm or more, with a groove placed opposite the plate thickness, typically using mechanized or automated arc welding methods for materials less than 200 mm thick. Over the past half-century, extensive research has led to significant developments in both welding methods and materials, making narrow gap welding an essential part of industrial production across many countries.
Narrow gap welding is classified based on the process used. For example, NG-SAW (Narrow Gap Submerged Arc Welding) commonly uses wires with diameters ranging from 2 to 5 mm, with 3 mm being optimal. The choice of welding scheme—whether single-pass or multi-pass—depends on several factors, including flux type, wire positioning, and welding parameters. Single-pass welding, though efficient, requires precise control and specialized fluxes, which limits its adaptability. Multi-pass welding, on the other hand, offers greater reliability and fewer defects, even though it comes at a higher cost.
Submerged arc welding, which forms the basis of many narrow gap techniques, inherits its advantages, such as high arc power and minimal spatter. However, it also carries limitations, such as difficulties in slag removal during single-pass welding and challenges in maintaining consistent weld geometry. Despite these issues, submerged arc welding remains one of the most mature and widely used methods in narrow gap applications.
In addition to SAW, other methods like Gas Metal Arc Welding (GMAW), Tungsten Inert Gas (TIG) welding, and Electroslag Welding (ESW) are also employed in narrow gap welding. Each has its own set of benefits and drawbacks. For instance, GMAW allows for better control over the weld pool, while TIG produces high-quality, defect-free welds but at a slower pace. ESW is particularly effective for thick sections and can be used on a variety of metals, including aluminum and titanium.
In recent years, advancements in automation, computer control, and power supply technologies have significantly enhanced the performance and reliability of narrow gap welding systems. Innovations such as pulsed jet transition, surface tension transfer, and advanced tracking systems have made it possible to achieve higher precision and lower spatter rates. These improvements have contributed to the growing adoption of narrow gap welding in industries like pressure vessels, shipbuilding, and structural steelwork.
Despite its many advantages, narrow gap welding still faces challenges, particularly in terms of economic viability for thinner materials and the need for specialized equipment. However, ongoing research and development continue to push the boundaries of this technology, promising even greater efficiency, quality, and cost-effectiveness in the future. As industries move toward more complex and demanding applications, narrow gap welding is expected to play an increasingly important role in modern manufacturing.