Abstract
This study investigates a parametric multi-objective optimization of the Tungsten Inert Gas-Metal Inert Gas (TIG-MIG) hybrid welding of AISI 1008 mild steel joints. A combined grey relational system theory and the Taguchi method was used for process optimization towards achieving a set of process parameter that maximizes both ultimate tensile strength and 0.2% yield strength for structural applications. An L-9 orthogonal array based on the Taguchi method was adopted for the experimental design matrix. Grey relational grading system was used to establish a single grade for the responses. Mathematical models for first- and second-order regressions were developed and optimum process parameter combination that optimizes the response was obtained. From the results, the gas flow rate had the most significant influence on the responses with a percentage contribution of 39.77%. Also, the second-order regression models had a higher coefficient of determination (R2) compared to the first-order regression for the two responses and, thus, represents the best fit for the process. The grey relational grade was improved by 0.0489 through process optimization. The interactive effects of process parameters and their effects on the responses are also illustrated by response surface plots. This study shows the effectiveness of the grey relational grading system in achieving a multi-objective optimization for the TIG-MIG welding process.
Highlights
The quest for high productivity and high-quality welding processes for engineering applications necessitated the modification of the conventional welding processes and the introduction of hybrid welding processes
Zhang et al (2017) carried out a comparative study on the joint quality of dissimilar aluminium and titanium welds produced by the Tungsten Inert Gas-Metal Inert Gas (TIG-method is Voltage (MIG)) double-sided arc welding-brazing process and the MIG welding process
Ye et al (2017) reported that sound and excellent front and back bead between aluminium and low carbon steel can be achieved through the MIG-TIG double-sided arc welding process compared to the single MIG welding process, even at lower heat input
Summary
The quest for high productivity and high-quality welding processes for engineering applications necessitated the modification of the conventional welding processes and the introduction of hybrid welding processes. Zhang et al (2017) carried out a comparative study on the joint quality of dissimilar aluminium and titanium welds produced by the Tungsten Inert Gas-Metal Inert Gas (TIG-MIG) double-sided arc welding-brazing process and the MIG welding process. Both welding processes were carried out at the same welding heat input value. The authors claimed that the double-sided arc welding-brazing is more feasible for producing stronger dissimilar joints of mild steel and aluminium This is because the tensile strength of the hybrid process showed a better value (148 MPa) than that of the single MIG process (56 MPa). The study attributed the high tensile strength of the hybrid process to the even distribution of the welding heat (which helped in impeding intermetallic growth) and the double shielding (which prevented crack formation and pores in the weld)
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