scholarly journals Representation of gas metal arc pulsed welding process behavior on bead geometry: a study of leading variables

2021 ◽  
Vol 2139 (1) ◽  
pp. 012008
Author(s):  
J L Lázaro Plata ◽  
C S Sánchez Rincón
Keyword(s):  
Welding Process ◽  
Weld Bead ◽  
Structural Quality ◽  
Welding Parameters ◽  
Bead Geometry ◽  
Automatic Welding ◽  
Cored Wire ◽  
Experimental Development ◽  
Welding Processes

Abstract Gas metal arc welding is one of the most influential processes in the production and repair of structures and equipment; therefore, the need to improve the productivity and quality of welded joints has led to the development of techniques for good control of welding parameters. Also, the development of semi-automatic welding processes led to the control of one of the variables such as pulsed current; this technique is characterized by a lower heat input and lower energy expenditure, which directly influences the structural quality of the welded joint and the geometry of the weld bead. This work focused on evaluating the effects of various welding operating parameters using the central composite design tool based on the response surface methodology; next, the experimental development employed an inverter type power source for weld depositions, a commercial grade Stargold clean 96% Ar and 4% CO2 shielding gas at the rate of 15 L/min stationary arc, a 1.2 mm metal cored wire for welding deposit and a carbon steel base plate with a thickness of 6 mm. During the welding process, the torch was kept at a 90° inclination and a 16 mm stroke. To examine the adequacy of the empirical models and the significance of the regression coefficients, the variance analysis was employed. Consequently, the graphs were obtained through the determination of the model; from the statistical results obtained, it was shown that the above models were adequate to predict the weld width, bead height, and penetration within the range of variables studied. Furthermore, it was observed that the wire feed rate it has a very marked effect on weld bead geometry, followed by frequency pulse and peak current; finally, the effectiveness of employing these methodologies for the management of variables attributing to the execution of welding tasks with higher accuracy was demonstrated.

scholarly journals Parametric Optimization of the GMAW Welding Process in Thin Thickness of Austenitic Stainless Steel by Taguchi Method

2021 ◽  
Vol 11 (18) ◽  
pp. 8742
Author(s):  
Glauco Nobrega ◽  
Maria Sabrina Souza ◽  
Manuel Rodríguez-Martín ◽  
Pablo Rodríguez-Gonzálvez ◽  
João Ribeiro
Keyword(s):  
Stainless Steel ◽  
Taguchi Method ◽  
Gas Metal Arc Welding ◽  
Welding Process ◽  
Welding Parameters ◽  
Root Penetration ◽  
Automatic Welding ◽  
Bead Width ◽  
Welding Processes

In the present work, an analysis of different welding parameters was carried out on the welding of stainless-steel thin thickness tubes by the Gas Metal Arc Welding (GMAW) process. The influence of three main parameters, welding voltage, movement angle, and welding current in the quality of the welds, was studied through a specifically designed experimental process based on the establishment of three different levels of values for each of these parameters. Weld quality is evaluated using destructive testing (macrographic analysis). Specifically, the width and root penetration of the weld bead were measured; however, some samples have been disregarded due to welding defects outside the permissible range or caused by excessive melting of the base metals. Data are interpreted, discussed, and analyzed using the Taguchi method and ANOVA analysis. From the analysis of variance, it was possible to identify the most influential parameter, the welding voltage, with a contribution of 43.55% for the welding penetration and 75.26% for the bead width, which should be considered in the designs of automatic welding processes to improve the quality of final welds.

scholarly journals Numerical Simulation Mode of Spot Contact Welding Processes

2021 ◽  
pp. 85-91
Author(s):  
А.С. Угловский ◽  
И.М. Соцкая ◽  
Е.В. Шешунова
Keyword(s):  
Spot Welding ◽  
Low Carbon Steel ◽  
Welding Process ◽  
Welding Parameters ◽  
Low Carbon ◽  
Detailed Data ◽  
Welding Quality ◽  
Welding Processes ◽  
Contact Welding

Цель рассмотрения численного метода заключалась в получении подробных данных, позволяющих оценить проведение сварочного процесса: изменение объёма сварного шва, радиуса сварного шва, радиуса зоны термического влияния. При проведении моделирования авторами выведены зависимости параметров точечной сварки низкоуглеродистой стали толщиной до 3,2 мм. Данные зависимости будут определять качество сварных швов. Соответствующее сочетание параметров точечной сварки обеспечит прочное соединение и хорошее качество сварки. The purpose of the numerical method consideration was to obtain detailed data allowing evaluating the performance of the welding process: changing the volume of the weld, the radius of the weld, the radius of the weld-affected zone. During the simulation the authors have derived dependencies of the parameters of spot welding of low-carbon steel up to 3.2 mm thick. These dependencies will determine the quality of the welds. The correct combination of spot welding parameters will ensure a firm joint and good welding quality.

scholarly journals Prediction and Optimization of Weld Bead Geometry

2019 ◽  
Vol 8 (10) ◽  
pp. 2735-2742
Keyword(s):  
Weld Bead ◽  
Welding Parameters ◽  
Bead Geometry ◽  
Weld Bead Geometry ◽  
Bead Width ◽  
Current Voltage ◽  
Weld Parameters ◽  
Curvilinear Regression ◽  
Travel Rate

Bead geometry plays very important role in predicting the quality of weld as cooling rate of the weld depends on the height and bead width, also bead geometry determines it’s residual stresses and distortion. Weld bead geometries are outcomes of several welding parameters taken into consideration. If arc travel is high and arc power is kept low it will produce very low fusion. If electrode feed rate is kept higher width is also found to be on higher side which makes bead tto flat. Also, the parameters like current, voltage, arc travel rate, polarity affects weld bead geometry. Hence, this paper uses techniques like ANN, linear regression and curvilinear regression for predictions of weld bead geometry and their relations with different weld parameters. I. INTRODU

scholarly journals Modeling and Optimization of Weld Bead Profile with Varied Welding Stages for Weathering Steel A606

2021 ◽  
Author(s):  
Dawei Zhao ◽  
Yuriy Bezgans ◽  
Nikita Vdonin ◽  
Liudmila Radionova ◽  
Vitaly Bykov
Keyword(s):  
Desirability Function ◽  
Research Work ◽  
Welding Process ◽  
Weld Bead ◽  
Welding Parameters ◽  
Weathering Steel ◽  
Bead Geometry ◽  
Feed Speed ◽  
Geometric Features ◽  
Weld Bead Geometry

Abstract The profile of the welding bead changes with the welding process parameters during the gas metal arc welding (GMAW) process, the reinforcement disappears and the penetration becomes sunken when the excessive welding heat input is applied. However, little research work is specially planned to cope with the studying of welding bead at these stages. A systematic studying of the relationships among the welding process variables and welding bead geometric features and optimization of the welding quality is presented. The influences of the welding technological parameters (voltage, welding speed, and wire feed speed) on the welding geometry were revealed and the models correlating them were established. The features of the weld bead geometry were composed of top reinforcement width, top reinforcement height, penetration depth, bottom reinforcement width, and bottom reinforcement height. By the desirability function approach, the recommendation of suitable welding parameters to meet the contradicting demands of multiple bead geometric features is fulfilled. The microstructure in different welding regions and mechanical performances of the welding joints produced by the verification test were also studied.

The Development of Control System for Lowcost Automatic Welding Equipment of Aluminum Radiator Head

2012 ◽  
Vol 485 ◽  
pp. 12-15
Author(s):  
Ju Lian Ma ◽  
Hao Bin Zhou ◽  
Xiang Qian Xu ◽  
Xiao Wei Wang
Keyword(s):  
Control System ◽  
Low Cost ◽  
Welding Process ◽  
Welding Parameters ◽  
Automatic Welding ◽  
Control Board ◽  
Manual Operation ◽  
Welding Equipment ◽  
Production Site

Considering the characteristic of welding process for all-aluminum radiator and meeting the needs of Chinese production site, low-cost automatic welding equipment for aluminum radiator head has been designed, and this paper focuses on its electrical controls. The microkernel of main control board is C8051F020. Based on this board the subsystems for the entire piece of this equipment has been established, which include LCD，automatic welding, manual operation , welding parameters setting ,etc. Through trial runs of the machine, it indicates that the design of the electrical controls for the equipment is rational, full-featured, and works reliably and efficiently. And the quality of welding is well.

scholarly journals REPLACEMENT OF MANUAL GMAW WELDING BY FCAW SEMI-AUTOMATIC WELDING

2021 ◽  
Vol 2021 (2) ◽  
pp. 4342-4347
Author(s):  
MARIAN SIGMUND ◽  
◽  
TADEAS CICHA
Keyword(s):  
Carbon Steel ◽  
Arc Welding ◽  
Gas Metal Arc Welding ◽  
Welding Parameters ◽  
Automatic Welding ◽  
Cored Wire ◽  
Metal Arc Welding ◽  
Flux Cored Arc Welding ◽  
Welding Procedure ◽  
Welding Processes

The article describes a replacement and benefits between manual gas metal arc welding (GMAW) with solid wire and semi-automatic flux-cored arc welding (FCAW) with metal flux-cored wire for a specific application of a welded steel compensator used for connecting piping systems to form larger units. For the replacement of the technologies and improvement of the welding efficiency and productivity a specific type of carbon steel mounting insert, DN300 PN16, was selected. Since these pressure parts are subject to the directive 2014/68/EU, both the welding processes have to meet the same welding quality requirements. In particular, they are the welding procedure qualification report (WPQR) and the welder’s or welding operator’s qualification in accordance with valid European standards. Based on this requirement, a sample was selected so that it would cover the widest possible range of carbon steel mounting inserts produced. This article describes the whole experiment including the selection of the right equipment and filler material, finding the ideal welding parameters, and the subsequent qualification of the welding procedure and the operator with emphasis on the largest possible increase in the welding speed and productivity for these specific weldments.

scholarly journals Mathematical Model for Prediction and Optimization of Weld Bead Geometry in All-Position Automatic Welding of Pipes

Metals ◽  
2018 ◽  
Vol 8 (10) ◽  
pp. 756 ◽  
Author(s):  
Baoyi Liao ◽  
Yonghua Shi ◽  
Yanxin Cui ◽  
Shuwan Cui ◽  
Zexin Jiang ◽  
...  
Keyword(s):  
Statistical Models ◽  
Weld Bead ◽  
Duty Ratio ◽  
Welding Parameters ◽  
Bead Geometry ◽  
Automatic Welding ◽  
Weld Bead Geometry ◽  
Surface Method ◽  
Copper Nickel Alloy ◽  
Welding Position

In this study all-position automatic tungsten inert gas (TIG) welding was exploited to enhance quality and efficiency in the welding of copper-nickel alloy pipes. The mathematical models of all-position automatic TIG weld bead shapes were conducted by the response surface method (RSM) on the foundation of central composition design (CCD). The statistical models were verified for their significance and adequacy by analysis of variance (ANOVA). In addition, the influences of welding peak current, welding velocity, welding duty ratio, and welding position on weld bead geometry were investigated. Finally, optimal welding parameters at the welding positions of 0° to 180° were determined by using RSM.

Mathematical Expression for the Prediction of Penetration in Butt Joints for Duplex Stainless Steel SAF-2205

2003 ◽  
Author(s):  
Mari´a Carolina Payares ◽  
Minerva Dorta Almenara
Keyword(s):  
Stainless Steel ◽  
Arc Welding ◽  
Welding Process ◽  
Weld Bead ◽  
Welding Parameters ◽  
Linear Regression Method ◽  
Bead Geometry ◽  
Butt Joints ◽  
Weld Bead Geometry ◽  
Saf 2205

In order to understand the mechanism of weld bead formation, a relationship between arc welding parameters and weld bead geometry must be established. This relationship is also necessary to forecast penetration variables allowing to optimize welding parameters for particular applications. Specifically in duplex stainles steel SAF-2205 welding, the influence of arc current, arc voltage and welding speed on the penetration have been empirically studied. In this research, using a multiple linear regression method, the statistical analyses produced twelve (12) potential function dependent of these welding parameters that determines the weld bead geometry in butt joints of DSS SAF 2205 using GAs Metal Arc Welding process. the mathematical model gave as a result, a very approximate contour of the weld bead geometry between the established ranges of welding parameters used. Also, the influence of these variables on the weld panetration is studied, providing with new evidence in stainless steel welding.

scholarly journals Different Methods for Predicting and Optimizing Weld Bead Geometry with Mathematical Modeling and ANN Technique

2019 ◽  
Vol 8 (10) ◽  
pp. 2761-2766
Keyword(s):  
Weld Bead ◽  
Welding Parameters ◽  
Bead Geometry ◽  
Weld Bead Geometry ◽  
Bead Width ◽  
Current Voltage ◽  
Modeling Techniques ◽  
Weld Parameters ◽  
Travel Rate

Bead geometry plays very important role in predicting the quality of weld as cooling rate of the weld depends on the height and bead width, also bead geometry determines it’s residual stresses and distortion. Weld bead geometries are outcomes of several welding parameters taken into consideration. If arc travel is high and arc power is kept low it will produce very low fusion. If electrode feed rate is kept higher width is also found to be on higher side which makes bead tto flat. Also, the parameters like current, voltage, arc travel rate, polarity affects weld bead geometry. Hence, this paper is a review of different experimentations and modeling techniques regarding predictions of weld bead geometry and their relations with different weld parameters.

Correlation between Welding Parameter and Bead Geometry of Flux Cored Arc Welding (FCAW) in Horizontal Position (2F)

2014 ◽  
Vol 564 ◽  
pp. 549-554
Author(s):  
Nik Mohd Baihaki Abd Rahman ◽  
Abdul Ghalib Tham ◽  
Sunhaji Kiyai Abas ◽  
Razali Hassan ◽  
Yupiter H.P. Manurung ◽  
...  
Keyword(s):  
Heat Input ◽  
Arc Welding ◽  
Weld Bead ◽  
Welding Parameter ◽  
Welding Parameters ◽  
Bead Geometry ◽  
Automatic Welding ◽  
Trend Line ◽  
Flux Cored Arc Welding ◽  
Good Prediction Accuracy

A robotic system can convert the semi-automatic Flux Cored Arc Welding (FCAW) to an automatic welding system. The critical requirement in automated welding process is that the optimal welding parameter has to be set before welding start. These input welding parameters cannot be easily guessed unless one has the knowledge. Only very specific range of heat input that produces quality weld deposition. The correlation between the heat input and fillet weld bead can be displayed in a unique trend-line graph. Mathematical formulas that match the trend-line profile can be used to create a prediction calculator that displays the digital values of weld bead geometry when welded at a specific range of heat input. Small Mean Absolute Deviation between predicted and measured geometry means good prediction accuracy. With this correlation chart, the welding parameter for quality weld bead can be selected and the geometry of FCAW weld deposition in 2F position can be predicted accurately without trial and error.

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