Abstract
Hybridization suggests combination of two or more conventional processes in synergy assuring a composite outcome as an improvement over the conventional practice. This study is an attempt to study and benchmark hybrid TIG-MAG arc welding process by comparison against conventional MAG for mild steel. The comparison has been studied at microstructural level on phase distribution and micro-hardness. It also compares the impact strength of the welded joints at sub-zero temperatures. The comparison further judges the devised hybrid process against the conventional MAG based on power consumption vis-a-vis improvement in productivity in terms of the rate of metal deposition. The study has reported average 11% savings on power consumption with 58% increase in productivity for hybrid arc welding which reassures its application to be extended beyond metal joining to surface processing. The microstructure and the metal deposition studies make use of bead on plate welding. The impact strength study deploys a thorough joint preparation and the subsequent sample extractions and conduct of Charpy impact test as per ASTM E23 and ASME section II-C. The study also discusses the indigenously developed straight shank arc welding torches to suit process automation.
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