Parametric Optimization of Gas Metal Arc Welding Processes by Using Factorial Design Approach

Manoj Singla, Dharminder Singh, Dharmpal Deepak

Department of Mechanical Engg., R.I.E.I.T.,Railmajra, 144533, INDIA.

DOI: 10.4236/jmmce.2010.94026                

Abstract

Gas Metal Arc Welding is a process in which the source of heat is an arc format between consumable metal electrode and the work piece with an externally supplied gaseous shield of gas either inert such as argon, helium. This experimental study aims at optimizing various Gas Metal Arc welding parameters including welding voltage, welding current, welding speed and nozzle to plate distance (NPD) by developing a mathematical model for sound weld deposit area of a mild steel specimen. Factorial design approach has been applied for finding the relationship between the various process parameters and weld deposit area. The study revealed that the welding voltage and NPD varies directly with weld deposit area and inverse relationship is found between welding current and speed with weld deposit area.

Keywords

Gas Metal Arc Welding; Factorial Design Approach; Weld Deposit Area.

Conflicts of Interest

The authors declare no conflicts of interest.

References

[1]	E. Karadeniz, Ozsarac, U. and Yildiz, C., “The effect of process parameters on penetration in gas metal arc welding process”, Materials and Design, 2007 , Vol 28 ,Issue 2 , pp. 649-656.
[2]	M. Suban and J. Tusek, “Methods for the determination of arc stability”, Journal of Materials Processing Technology, 2003, pp. 430-437.
[3]	T.P. Quinn, C. Smith, C.N. McCowan, E. Blachowiak, R.B. Madigan, “Arc Sensing for Defects in Constant-Voltage Gas Metal Arc Weldiing”, Welding Journal, 1999, Vol. 78,pp. 322-328.
[4]	P. J. Hewitt and M. G. Madden, “Chromium in welding process parameters and hexavalent MIG Fume.”, Ann. Occup. Hyg.,1986, Vol. 30, No. 4, pp. 427-434.
[5]	K.C. Jang, D.G. Lee, J.M. Kuk and I.S. Kim, “Welding and environmental test condition effect in weldability and strength of Al alloy”, Journal of Materials Processing Technology, 2005, Vol. 164-165, pp.1038-1045.
[6]	P. Praveen, P.K.D.V. Yarlagadda, “Meeting challenges in welding of aluminum alloys through pulse gas metal arc welding”, Journal of Materials Processing Technology, 2005, pp.1106-1112.
[7]	J. M. Kuk, K. C. Jang, D. G. Lee, I. S. Kim, “Effects of temperature and shielding gas mixture on fatigue life of 5083 aluminum alloy”, Journal of Materials Processing Technology, 2004, Vol. 155-156, , pp.1408-1414.
[8]	N. Murugan, R. S. Parmar, “Effects of MIG process parameters on the geometry of the bead in the automatic surfacing of stainless steel”, Journal of Materials Processing Technology, 1994, Vol. 41, pp. 381-398.
[9]	P. Praveen, P.K.D.V. Yarlagadda, M.J. Kang, “Advancements in pulse gas metal arc welding”, Journal of Materials Processing Technology, Vol. 164-165, 2005, pp.1113-1119.
[10]	L. Quintino and C.J. Allum, “Pulsed GMAW: interactions between process parameters –part 1”, Welding Met. Fabrication, Vol. 85, 1981, pp. 5–9.
[11]	S. Ueguri, K. Hara, H. Komura, “Study of metal transfer in pulsed GMA welding”, Weld. J., 1985, Vol. 64, pp. 242–50.
[12]	Z. Smati, Automated pulsed MIG welding, Metal Construction, 1985, Vol. 18, pp 38–44.
[13]	Y. S. Kim, “Metal transfer in gas metal arc welding”, PhD Thesis, 1989, MIT: USA.
[14]	J. H. Waszink, M. J. Piena, “Experimental investigation of drop detachment and drop velocity in GMAW”, Welding Journal , Vol. 65 ,1986 , pp.289–98.
[15]	L. A. Jones, T. W. Eager, J. H. Lang, “Magnetic forces acting on molten drops in gas metal arc welding”, J. Phys. D. Appl. Phys., Vol. 31 ,1998, pp. 93-106.
[16]	J. H. Nixon, J. Norrish, “Determination of pulsed MIG process parameters”, Welding and Metal Fabrication, 1988 , pp. 4-7.
[17]	F. Wang, W. K. Hou, S. J. Hu, E Kannatey-Asibu, W. W. Schultz, P. C. Wang, “Modelling and analysis of metal transfer in gas metal arc welding”, J. Phys. D: Appl. Phys., Vol. 36 , 2003 , pp.1143-1152.
[18]	F. Zhu, “A comprehensive dynamic model of the gas metal arc welding process”, PhD Thesis, 2003, University of Missouri- Rolla USA .
[19]	M. Goodarzi, “Mathematical modelling of gas tungsten arc welding (GTAW) and gas metal arc welding (GMAW) processes”, PhD Thesis, 2003, University of Toronto Canada.
[20]	Ghosh P.K., Gupta S.R., Gupta P.C., Rathi R., “Fatigue characteristics of pulsed MIGwelded Al-Zn-Mg alloy”, Journal of Material Science , Vol. 26 , Issue 22 ,1991, pp. 6161-6170.