Mathematical Modeling for the Prediction of Depth of Penetration in Double Pulse GMA Welding Using Fractional Factorial Method

Abstract

The quality of weld joint is directly influenced by the input process parameters influenced by various process parameters during welding. The weld quality can be decided by bead geometry viz., depth of penetration and bead width. Inadequate depth of penetration will lead to failure of the welded structure. This paper presents the development of mathematical model for the prediction of depth of penetration of weld bead geometry in pulsed gas metal arc welding process in double pulse mode. The model is based on experimental data .In this investigation four input process parameters wire feed rate, ratio of wire feed rate to travel speed, amplitude and double pulse frequency are considered. The experiments were conducted on 6mm thickness plate of 5083 H111 aluminum alloy using fractional factorial design of experiments. The mathematical model for depth of penetration is developed using multiple nonlinear regression. The developed model is then compared with experimental results and it is found that the results obtained from mathematical model are accurate. The obtained results help in selecting quickly the process parameters to achieve the desired quality.