Experimental investigation on cladding with metal cored wire using GMAW process and parametric optimization

2021 ◽  
Author(s):  
Ashish Kaushik ◽  
Vivek Singh ◽  
Bishub Choudhury ◽  
Som Ashutosh ◽  
Muthumari Chandrasekaran
Keyword(s):  
Process Parameters ◽  
Optimal Parameter ◽  
Thick Layer ◽  
Filler Material ◽  
Welding Parameters ◽  
Optimization Approach ◽  
Parameter Setting ◽  
Cored Wire ◽  
Corrosion Resistant ◽  
Fitness Value

Abstract Cladding is widely used in manufacturing industries for the production of pressure vessel by depositing thick layer of filler material for providing corrosion resistant-surface. The use of metal cored wire in gas metal arc welding (GMAW) process is popular due to its higher deposition rate and productivity. This work investigates the effect of process parameters on the deposition of cladding layer with ER 309L metal core wire (as filler material) on a corrosion resistant material (IS 2062). The welding parameters viz., wire feed rate (WFR), voltage (V), welding speed (S) and nozzle to plate distance (NTD) are employed as process parameters while penetration (P), bead width (W), reinforcement (R), weld penetration, shape factor (WPSF) and weld reinforcement form factor (WRFF) as welding responses. The predictive model developed for P, W, R, WPSF, and WRFF using the response surface methodology (RSM) approach is found adequate at 95% confidence interval. The validation results for the developed model results in a model accuracy (MA) of 92.82%, 96.34%, 91.47% 88.98% and 87.75% for model P, W, R, WPSF, and WRFF respectively and it shows higher predictability and accuracy. The process parameters are optimized simultaneously with integrated optimization approach using RSM with Jaya algorithm and obtain optimal solution in less than 20 number of iterations. The minimum fitness value obtained as 1.3008 at an optimal parameter setting of WFR=12m/min, V=26V, S=280mm/min, NTD=10mm. The validation result at the optimal parameter setting results in an improvement of 6.45%, 11.29%, 13.58%, 16.07%, 15.38% is noted for P, W, R, WPSF, and WRFF respectively.

scholarly journals Optimization of GMAW Process Parameters Using Particle Swarm Optimization

2013 ◽  
Vol 2013 ◽  
pp. 1-10 ◽  
Author(s):  
P. Sreeraj ◽  
T. Kannan ◽  
Subhashis Maji
Keyword(s):  
Particle Swarm Optimization ◽  
Carbon Steel ◽  
Process Parameters ◽  
Gas Metal Arc Welding ◽  
Particle Swarm ◽  
Thick Layer ◽  
Bead Geometry ◽  
Low Carbon ◽  
Swarm Optimization ◽  
Corrosion Resistant

To improve the corrosion-resistant properties of carbon steel cladding process is usually used. It is a process of depositing a thick layer of corrosion resistant material-over carbon steel plate. Most of the engineering applications require high strength and corrosion resistant materials for long-term reliability and performance. By cladding, these properties can be achieved with minimum cost. The main problem faced in cladding is the selection of optimum combinations of process parameters for achieving quality clad and hence good clad bead geometry. This paper highlights an experimental study to optimize various input process parameters (welding current, welding speed, gun angle, contact tip to work distance, and pinch) to get optimum dilution in stainless steel cladding of low-carbon structural steel plates using gas metal arc welding (GMAW). Experiments were conducted based on central composite rotatable design with full-replication technique and mathematical models were developed using multiple regression method. The developed models have been checked for adequacy and significance. Using particle swarm optimization (PSO) the parameters were optimized to get minimal dilution.

scholarly journals Estimation of Optimum Dilution in the GMAW Process Using Integrated ANN-GA

2013 ◽  
Vol 2013 ◽  
pp. 1-17 ◽  
Author(s):  
P. Sreeraj ◽  
T. Kannan ◽  
Subhashis Maji
Keyword(s):  
Carbon Steel ◽  
Process Parameters ◽  
Gas Metal Arc Welding ◽  
Thick Layer ◽  
Welding Current ◽  
Minimum Cost ◽  
High Strength ◽  
Bead Geometry ◽  
Low Carbon ◽  
Corrosion Resistant

To improve the corrosion resistant properties of carbon steel, usually cladding process is used. It is a process of depositing a thick layer of corrosion resistant material over carbon steel plate. Most of the engineering applications require high strength and corrosion resistant materials for long-term reliability and performance. By cladding these properties can be achieved with minimum cost. The main problem faced on cladding is the selection of optimum combinations of process parameters for achieving quality clad and hence good clad bead geometry. This paper highlights an experimental study to optimize various input process parameters (welding current, welding speed, gun angle, and contact tip to work distance and pinch) to get optimum dilution in stainless steel cladding of low carbon structural steel plates using gas metal arc welding (GMAW). Experiments were conducted based on central composite rotatable design with full replication technique, and mathematical models were developed using multiple regression method. The developed models have been checked for adequacy and significance. In this study, artificial neural network (ANN) and genetic algorithm (GA) techniques were integrated and labeled as integrated ANN-GA to estimate optimal process parameters in GMAW to get optimum dilution.

scholarly journals Just-in-Time Adaptive Algorithm for Optimal Parameter Setting in 802.15.4 WSNs

2016 ◽  
Vol 10 (4) ◽  
pp. 1-26 ◽  
Author(s):  
Simone Brienza ◽  
Manuel Roveri ◽  
Domenico De Guglielmo ◽  
Giuseppe Anastasi
Keyword(s):  
Adaptive Algorithm ◽  
Optimal Parameter ◽  
Just In Time ◽  
Parameter Setting

Influence of Rotary Friction Welding Parameters on Tensile Strength and Length of TMAZ of Dissimilar Welded Joints from 32G2 and 40KhN Steels

2021 ◽  
Vol 410 ◽  
pp. 299-305
Author(s):  
Artem S. Atamashkin ◽  
Elena Y. Priymak ◽  
Elena A. Kuzmina
Keyword(s):  
Tensile Strength ◽  
Base Metal ◽  
Process Parameters ◽  
Welded Joints ◽  
Friction Welding ◽  
Tensile Tests ◽  
Welding Parameters ◽  
Rotary Friction Welding ◽  
Study Results ◽  
Friction Pressure

In this work, pipe billets with a diameter of 73 mm and a wall thickness of 9 mm from steels 32G2 and 40KhN are friction welded with an aim to optimize the process parameters. The friction pressure, the forging pressure and the length of the fusion varied. After the implementation of various welding modes, tensile tests and metallographic studies were carried out. The optimal welding parameters have been established, which make it possible to obtain tensile strength at the level of the 32G2 base metal. The study results of the microstructure and SEM fractographs after the optimal welding mode are presented.

scholarly journals A Cybernetic Approach to Modeling Lipid Metabolism in Mammalian Cells

Processes ◽  
2018 ◽  
Vol 6 (8) ◽  
pp. 126 ◽  
Author(s):  
Lina Aboulmouna ◽  
Shakti Gupta ◽  
Mano Maurya ◽  
Frank DeVilbiss ◽  
Shankar Subramaniam ◽  
...  
Keyword(s):  
Mammalian Cells ◽  
Metabolic Regulation ◽  
Metabolic Flux ◽  
Optimal Parameter ◽  
Gene Knockout ◽  
Model Parameters ◽  
Mouse Bone Marrow ◽  
Optimization Approach ◽  
Substrate Uptake ◽  
Data Set

The goal-oriented control policies of cybernetic models have been used to predict metabolic phenomena such as the behavior of gene knockout strains, complex substrate uptake patterns, and dynamic metabolic flux distributions. Cybernetic theory builds on the principle that metabolic regulation is driven towards attaining goals that correspond to an organism’s survival or displaying a specific phenotype in response to a stimulus. Here, we have modeled the prostaglandin (PG) metabolism in mouse bone marrow derived macrophage (BMDM) cells stimulated by Kdo2-Lipid A (KLA) and adenosine triphosphate (ATP), using cybernetic control variables. Prostaglandins are a well characterized set of inflammatory lipids derived from arachidonic acid. The transcriptomic and lipidomic data for prostaglandin biosynthesis and conversion were obtained from the LIPID MAPS database. The model parameters were estimated using a two-step hybrid optimization approach. A genetic algorithm was used to determine the population of near optimal parameter values, and a generalized constrained non-linear optimization employing a gradient search method was used to further refine the parameters. We validated our model by predicting an independent data set, the prostaglandin response of KLA primed ATP stimulated BMDM cells. We show that the cybernetic model captures the complex regulation of PG metabolism and provides a reliable description of PG formation.

scholarly journals The Optimum Process Parameter of Dissimilar Metal AA6061 – AISI304 Continuous Drive Friction Welding

2020 ◽  
Vol 55 (2) ◽  
Author(s):  
Totok Suwanda ◽  
Rudy Soenoko ◽  
Yudy Surya Irawan ◽  
Moch. Agus Choiron
Keyword(s):  
Tensile Strength ◽  
Response Surface ◽  
Process Parameters ◽  
Friction Welding ◽  
Welding Parameters ◽  
Optimum Process ◽  
Dissimilar Metals ◽  
Maximum Tensile Strength ◽  
Friction Pressure ◽  
Welding Processes

This article explains the use of the response surface method to produce the optimum tensile strength for the joining of dissimilar metals with the continuous drive friction welding method. The joining of dissimilar metals is one of the biggest challenges in providing industrial applications. Continuous drive friction welding has been extensively used as one of the important solid-state welding processes. In this study, the optimization of the friction welding process parameters is established to achieve the maximum tensile strength in AA6061 and AISI304 dissimilar joints via the response surface methodology. The effect of continuous drive friction welding parameters, which are friction pressure, friction time, upset pressure, and upset time, are investigated using response surface analysis. The design matrix factors are set as 27 experiments based on Box-Behnken. The 3D surface and the contour is plotted for this model to accomplish the tensile strength optimization. The optimization model of the tensile strength was verified by conducting experiments on the optimum values of the parameters based on the experimental data results. It can be denoted that the optimum process parameters settings were friction pressure = 25 MPa, friction time = 6 seconds, upset pressure = 140 MPa, and upset time = 8 seconds, which would result in a maximum tensile strength of 228.57 MPa.

Comparison between Modelled Influence of GMAW Parameters and Corresponding Mechanical Properties of Group 1 and 2 According to ISO/TR 15608 Steel T Joints

2021 ◽  
Vol 890 ◽  
pp. 17-24
Author(s):  
Aurel Valentin Bîrdeanu ◽  
Alin Constantin Murariu ◽  
Horia Florin Daşcău ◽  
Iuliana Duma
Keyword(s):  
Process Parameters ◽  
High Performance ◽  
Hsla Steel ◽  
Welding Process ◽  
High Strength ◽  
Industrial Applications ◽  
Steel Plates ◽  
Experimental Program ◽  
Welding Parameters ◽  
T Joints

Reproducibility in respect to welded structures realization is one of the main requirements for a wide variety of industrial applications. One of the international tendencies regarding the use of the steel is the replacing, in critical areas, of structural steels with high performance steel, e.g. with HSLA steels. The paper presents the results of a factorial designed experimental program focused on determining mathematical correlations between the GMAW process parameters for T joints of 4mm thick steel plates of structural (S235JR+AR according to SR EN 10025-2) and hot-rolled, high-strength low-alloy (HSLA) steel plates (S420MC according to EN 10025-4), respectively. A comparison between the obtained mathematical correlations that connect the welding parameters and the main mechanical characteristics is presented. The correlations can be used for applying the optimal combination of welding process parameters for realizing the T-joints of welded products.

Experimental Investigation on Laser Transmission Welding of Polycarbonate and Acrylic

2021 ◽  
pp. 160-180
Author(s):  
Dhiraj Kumar ◽  
Sudipta Paitandi ◽  
Arunanshu Shekhar Kuar ◽  
Dipankar Bose
Keyword(s):  
Mathematical Model ◽  
Process Parameters ◽  
Welding Speed ◽  
Laser Power ◽  
Optimum Parameter ◽  
Optimization Technique ◽  
Welding Process ◽  
Parameter Setting ◽  
Laser Transmission Welding ◽  
Weld Width

This chapter presents the effect of various process parameters, namely laser power, pulse frequency, and welding speed, on the weld shear strength and weld width using a diode laser system. Here, laser transmission welding of transparent polycarbonate and black carbon filled acrylic each of 2.8 mm thickness have been performed to create lap joint by using low power laser. Response surface methodology is applied to develop the mathematical model between the laser welding process parameters and the responses of weld joint. The developed mathematical model is tested for its adequacy using analysis of variance and other adequacy measures. It has been observed that laser power and welding speed are the dominant factor followed by frequency. A confirmation test has also been conducted to validate the experimental results at optimum parameter setting. Results show that weld strength of 34.3173 N/mm and weld width of 2.61547 mm have been achieved at optimum parameter setting using desirability function-based optimization technique.

scholarly journals Optimization of FCAW Parameters for Ferrite Content in 2205 DSS Welds Based on the Taguchi Design Method

2018 ◽  
Vol 2018 ◽  
pp. 1-7 ◽  
Author(s):  
Tianqi Li ◽  
Yingying Zhang ◽  
Lei Gao ◽  
Yunhao Zhang
Keyword(s):  
Mathematical Model ◽  
Process Parameters ◽  
Welding Speed ◽  
Design Method ◽  
Welding Current ◽  
Taguchi Design ◽  
Experimental Results ◽  
Ferrite Content ◽  
Welding Parameters ◽  
Torch Angle

This study presents the Taguchi design method with L9 orthogonal array which was carried out to optimize the flux-cored arc welding (FCAW) process parameters such as welding current, welding voltage, welding speed, and torch angle with reference to vertical for the ferrite content of duplex stainless steel (DSS, UNS S32205) welds. The analysis of variance (ANOVA) was applied, and a mathematical model was developed to predict the effect of process parameters on the responses. The results indicate that welding current, welding voltage, welding speed, torch angle with reference to vertical, and the interaction of welding voltage and welding speed are the significant model terms connected with the ferrite content. The ferrite content increases with the increase of welding speed and torch angle with reference to vertical, but decreases with the increase of welding current and welding voltage. Through the developed mathematical model, the target of 50% ferrite content in weld metal can be obtained when all the welding parameters are set at the optimum values. Finally, in order to validate experimental results, confirmation tests were implemented at optimum working conditions. Under these conditions, there was good accordance between the predicted and the experimental results for the ferrite content.

Sign in / Sign up

Export Citation Format

Share Document