scholarly journals Development of mathematical model and optimization of GMA welding parameters of IS 2062 grade A steel weldments

2021 ◽  
Vol 15 (56) ◽  
pp. 84-93
Author(s):  
Saadat Ali Rizvi ◽  
Wajahat Ali
Keyword(s):  
Mathematical Model ◽  
Gas Flow ◽  
Gma Welding ◽  
Welding Parameters ◽  
Feed Speed ◽  
Weld Quality ◽  
Gas Flow Rate ◽  
Arc Voltage ◽  
Wire Feed Speed ◽  
Wire Feed

In this experimental works, the effect of GMA welding process parameters, such as arc voltage, wire feed speed, and gas flow rate on the mechanical quality of IS 2062 structural steel of grade A has been studied. Process parameters play an important role in determining the weld quality. In this research work response surface methodology (RSM) technique via design expert (DOE) 12 version software was applied to determining the weld quality and also to develop a mathematical model that can predict the main effect of the above said parameters on weld quality i.e. toughness and hardness. A set of experiments has been conducted to collect the data using a central composite design and ANOVA was used to predict the impact of welding parameters on toughness and hardness and Comparison also made between the actual result and predicted value and from the result that is clear that toughness and hardness of weldment is significantly affected by arc voltage, wire feed speed, and follow by gas flow rate.

Modeling of Weld Dilution in Gas Metal Arc Welding Process Using Taguchi's Design of Experiments

2011 ◽  
Vol 110-116 ◽  
pp. 2963-2968 ◽  
Author(s):  
Masood Aghakhani ◽  
Ehsan Mehrdad ◽  
Ehsan Hayati ◽  
Maziar Mahdipour Jalilian ◽  
Arash Karbasian
Keyword(s):  
Mathematical Model ◽  
Arc Welding ◽  
Gas Flow ◽  
Gas Metal Arc Welding ◽  
Welding Process ◽  
Welding Parameters ◽  
Gas Flow Rate ◽  
Metal Arc Welding ◽  
Wire Feed ◽  
Plate Distance

Gas metal arc welding is a fusion welding process which has got wide applications in industry. In order to obtain a good quality weld, it is therefore, necessary to control the input welding parameters. In other words proper selection of input welding parameters in this process contribute to weld productivity. One of the important welding output parameters in this process is weld dilution affecting the quality and productivity of weldment. In this research paper using Taguchi method of design of experiments a mathematical model was developed using parameters such as, wire feed rate (W), welding voltage (V), nozzle-to-plate distance (N), welding speed (S) and gas flow rate (G) on weld dilution. After collecting data, signal-to-noise ratios (S/N) were calculated and used in order to obtain the optimum levels for every input parameter. Subsequently, using analysis of variance the significant coefficients for each input factor on the weld dilution were determined and validated. Finally a mathematical model based on regression analysis for predicting the weld dilution was obtained. Results show that wire feed rate (W),arc voltage (V) have increasing effect while Nozzle-to-plate distance (N) and welding speed (S) have decreasing effect on the dilution whereas gas Flow rate alone has almost no effect on dilution but its interaction with other parameters makes it quite significant in increasing the weld dilution

Optimization of Welding Parameters and Microstructure and Fracture Mode Characterization of GMA Welding by Using Taguchi Method on SS304H Austenitic Steel

2020 ◽  
Vol 22 (4) ◽  
pp. 1121-1132
Author(s):  
Saadat Ali Rizvi ◽  
Wajahat Ali
Keyword(s):  
Tensile Strength ◽  
Flow Rate ◽  
Fracture Mode ◽  
Gas Flow ◽  
Gma Welding ◽  
Welding Parameters ◽  
Optimum Process ◽  
Feed Speed ◽  
Gas Flow Rate ◽  
Tensile Test Specimen

AbstractThis study is centre on optimizing different welding parameters which affect the weldability of SS304H, Taguchi technique was employed to optimize the welding parameters and fracture mode characterization was studied. A number of experiments have been conducted. L9 orthogonal array (3×3) applied for it. Analysis of variance (ANOVA) and signal to noise ratio (SNR), a statistical technique was applied to determine the effect of different welding parameters such as welding current, wire feed speed and gas flow rate on weldability of SS304H. Tensile strength, toughness, micro hardness and mode of fracture was examined to determine weldability of SS304H and it was observed from result that welding voltage have major impact whereas gas flow rate has minour impact on ultimate tensile strength of the welded joints and optimum process parameters were found to be 23 V, 350 IPM travel speed of wire and 15 l/min gas flow rate for tensile strength and mode of fracture was ductile fracture for tensile test specimen.

Multi-properties optimization of welding parameters of wire arc additive manufacture in dissimilar joint of iron-based alloy and nickel-based superalloy using grey-based Taguchi method

2021 ◽  
pp. 095440622110089
Author(s):  
Yufeng Xia ◽  
Mengxia Peng ◽  
Haihao Teng ◽  
Yanhong Chen ◽  
Xue Zhang
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Welding Speed ◽  
Welding Parameters ◽  
Additive Manufacture ◽  
Feed Speed ◽  
Nickel Based Superalloy ◽  
Wire Feed Speed ◽  
Iron Based ◽  
Wire Feed

In order to adapt to the high temperature and heavy load process environment of large forgings, a novel die with “fist-like” structure was designed. The iron-based welding material (RMD248) as the “bone” layer and the nickel-based superalloy welding material (ERNiCr-3) as the “skin” layer were welded on the matrix by wire arc additive manufacture (WAAM). In this work, the grey based Taguchi methodology was used to optimize welding parameters (welding voltage, welding speed and wire feed speed) considering excellent multi-properties (hardness and ultimate tensile strength of high-temperature tensile test) of the dissimilar joint of RMD248 and ERNiCr-3. Further, analysis of variance was done to ascertain the influence of welding parameters on response parameters. Experimental results showed that welding speed was the most effective input parameter followed by wire feed speed and welding voltage. Finally, optimal result was verified through confirmation experiments. Meanwhile, the effect of welding speed on the microstructure and mechanical properties of joint was studied. The microstructures were characterized by optical microscopy (OM), energy dispersive spectrometer (EDS). The results indicated that the microstructure of RMD248 was consisted of more retained austenite at lower welding speed. For ERNiCr-3, the finer columnar crystal structure at higher welding speed was observed. At lower welding speed, the microhardness of RMD248 was just slightly lower, but that of ERNiCr-3 was significantly higher, and the ultimate tensile strength was higher. Therefore, the specimen at lower welding speed had better comprehensive mechanical properties.

The Theoretical and Experimental Investigation into Technological Parameters of High-Melting Metal Arc Spraying

2012 ◽  
Vol 6 (1) ◽  
pp. 60-67 ◽  
Author(s):  
C. H. Li ◽  
S. Wang ◽  
Y. C. Ding
Keyword(s):  
Arc Spraying ◽  
Feed Speed ◽  
High Melting ◽  
Technological Parameters ◽  
Arc Voltage ◽  
Distribution Rules ◽  
Wire Feed Speed ◽  
Arc Current ◽  
Speed Adjustment ◽  
Wire Feed

The experimental study is done for technological parameters of high-melting metal arc spraying to study the influence of spraying current, spraying voltage and wire feed voltage on spraying arc and the influence of spraying current on coating temperature and analyze theoretically the distribution rules of spray gun jet speed field and temperature field and their influencing factors. The results showed that the arc current increases along with arc voltage increase. The lower the spraying voltage is, the smaller the molten grain size becomes. However, if the arc voltage is lower than the minimum critical arc voltage of the material, the arc could not keep smooth burning. The spraying current has correspondence relationship with wire feed speed. The spraying current could be adjusted through wire feed speed adjustment.

scholarly journals Process Parameters Optimization for GMA Welding of AISI 1008 Steel Joints for Optimal Tensile Strength

2021 ◽  
Vol 31 (6) ◽  
pp. 349-354
Author(s):  
Cynthia S. Abima ◽  
Stephen A. Akinlabi ◽  
Nkosinathi Madushele ◽  
Esther T. Akinlabi
Keyword(s):  
Tensile Strength ◽  
Ultimate Tensile Strength ◽  
Flow Rate ◽  
Gas Flow ◽  
Gma Welding ◽  
Welding Current ◽  
Parameters Optimization ◽  
Gas Flow Rate ◽  
Arc Voltage ◽  
Input Parameters

Parameters optimization has become a gateway to achieving quality welds with improved properties desirable for construction and industrial applications. The complex interaction of welding input parameters requires process optimization to achieve optimal responses (s). This study reports the optimization of input parameters for Gas Metal Arc Welding (GMAW) for optimal ultimate tensile strength in AISI 1008 steel joints. Three levels of arc voltage, welding current, and gas flow rate were selected as input parameters, while the targeted output response is the ultimate tensile strength. Taguchi’s method with an L-9 orthogonal matrix was adopted for the process optimization. The MINITAB 17 software was used to analyze the response through analysis of variance and signal-to-noise ratio. The result revealed that the parameter settings for optimal tensile strength for the GMA welding of 6 mm thick AISI 1008 steel joint are arc voltage set at 30 V, current at 180 A, and gas flow rate set at 17 L/mm. The analysis of variance showed that the arc voltage had the most significant influence on the ultimate tensile strength with a 39.76% contribution, followed by the gas flow rate with 31.15%, while the welding current had 6.28% contributions. The surface plots show that a lower-level voltage, higher-level welding current, and higher-level gas flow rate favoured maximum ultimate tensile strength.

scholarly journals Optimization and Prediction of Ultimate Tensile Strength in Metal Active Gas Welding

2015 ◽  
Vol 2015 ◽  
pp. 1-5 ◽  
Author(s):  
Anusit Ampaiboon ◽  
On-Uma Lasunon ◽  
Bopit Bubphachot
Keyword(s):  
Tensile Strength ◽  
Ultimate Tensile Strength ◽  
Regression Model ◽  
Flow Rate ◽  
Welding Speed ◽  
Feed Rate ◽  
Gas Flow ◽  
Welding Parameters ◽  
Gas Flow Rate ◽  
Wire Feed

We investigated the effect of welding parameters on ultimate tensile strength of structural steel, ST37-2, welded by Metal Active Gas welding. A fractional factorial design was used for determining the significance of six parameters: wire feed rate, welding voltage, welding speed, travel angle, tip-to-work distance, and shielded gas flow rate. A regression model to predict ultimate tensile strength was developed. Finally, we verified optimization of the process parameters experimentally. We achieved an optimum tensile strength (558 MPa) and wire feed rate, 19 m/min, had the greatest effect, followed by tip-to-work distance, 7 mm, welding speed, 200 mm/min, welding voltage, 30 V, and travel angle, 60°. Shield gas flow rate, 10 L/min, was slightly better but had little effect in the 10–20 L/min range. Tests showed that our regression model was able to predict the ultimate tensile strength within 4%.

Correlation between wire feed speed and external mechanical constraint for enhanced process stability in underwater wet flux-cored arc welding

2018 ◽  
Vol 233 (10) ◽  
pp. 2061-2073 ◽  
Author(s):  
Jianfeng Wang ◽  
Qingjie Sun ◽  
Jiangkun Ma ◽  
Peng Jin ◽  
Tianzhu Sun ◽  
...  
Keyword(s):  
Welding Process ◽  
Electrical Signal ◽  
Feed Speed ◽  
Process Stability ◽  
Underwater Wet Welding ◽  
Extinction Process ◽  
Flux Cored Arc Welding ◽  
Wire Feed Speed ◽  
Wire Feed ◽  
Mechanical Constraint

It is a great challenge to improve the process stability in conventional underwater wet welding due to the formation of unstable bubble. In this study, mechanical constraint method was employed to interfere the bubble generated by underwater wet welding, and the new method was named as mechanical constraint assisted underwater wet welding. The aim of the study was to quantify the combined effect of wire feed speed and condition of mechanical constraint on the process stability in mechanical constraint assisted underwater wet welding. Experimental results demonstrated that the introduction of mechanical constraint not only suppressed the bubble without floating but also stabilized the arc burning process. The degree of influence of mechanical constraint, which changed with wire feed speed, played an important role during the mechanical constraint assisted underwater wet welding process. For all wire feed speeds, the fluctuations of welding electrical signal were decreased through introduction of mechanical constraint. The difference in the proportion of arc extinction process between underwater wet welding and mechanical constraint assisted underwater wet welding became less with increasing wire feed speed. At wire feed speed lower than 7.5 m/min, the improvement of process stability was very significant by mechanical constraint. However, the further improvement produced limited effect when the wire feed speed was greater than 7.5 m/min. The observation results showed that a better weld appearance was afforded at a large wire feed speed, corresponding to a lower variation coefficient.

Sign in / Sign up

Export Citation Format

Share Document