Prediction of Weld Bead Geometry in Plasma Arc Welding using Factorial Design Approach

K. Siva Prasad, Ch.Srinivasa Rao, D.Nageswara Rao

Department of Mechanical Engineering, Andhra University, Visakhapatnam, India.
Department of Mechanical Engineering,Anil Neeerukonda Institute of Technology & Sciences, Visakhapatnam, India..

DOI: 10.4236/jmmce.2011.1010068                

Abstract

The effect of various process parameters like welding current, torch height, welding speed and plasma gas flow rate on front melting width, back melting width and weld reinforcement of plasma arc welding on aluminum alloy is investigated by using factorial design approach. Variable polarity plasma arc welding is used for welding aluminum alloy. Trail experiments are conducted and the limits of the input process parameters are decided. Two levels and four input process parameters are chosen and experiments are conducted as per typical design matrix considering full factorial design. Total sixteen experiments are conducted and output responses are measured. The coefficients are calculated by using regression analysis and the mathematical models are constructed. By using the mathematical models the main and interaction effect of various process parameters on weld quality is studied.

Keywords

Plasma Arc Welding, Factorial Design, , Regression Analysis, Welding current, Welding speed, Torch height, Plasma gas flow rate, Front Melting Width, Back MeltingWidth, Weld Reinforcement.

Conflicts of Interest

The authors declare no conflicts of interest.

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