Artificial neural network optimisation of shielding gas flow rate in gas metal arc welding subjected to cross drafts when using alternating shielding gases

Abstract

This study implemented an iterative experimental approach in order to determine the shielding gas flow required to produce high-quality welds in the gas metal arc welding process with alternating shielding gases when subjected to varying velocities of cross drafts, thus determining the transitional zone where the weld quality deteriorates as a function of cross-draft velocity. An artificial neural network was developed using the experimental data that would predict the weld quality based primarily on shielding gas composition, alternating frequency and flow rate and cross-draft velocity, but also incorporated other important input parameters, including voltage and current. A series of weld trials were conducted to validate and test the robustness of the model generated. It was found that the alternating shielding gas process does not provide the same level of resistance to the adverse effects of cross drafts as a conventional argon/carbon dioxide mixture. The use of such a prediction tool is of benefit to industry in that it allows the adoption of a more efficient shielding gas flow rate, while removing the uncertainty of the resultant weld quality.