Optimizing the Parameters of TIG-MIG/MAG Hybrid Welding on the Geometry of Bead Welding Using the Taguchi Method

Cristian Schneider,Richard Lermen,Camila Lisboa,Rodrigo Silva

doi:10.3390/jmmp1020014

Cristian Schneider, Richard Lermen + Show 2 more

Open Access

https://doi.org/10.3390/jmmp1020014

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Abstract

The main aim of this work was to evaluate the influence and optimize the factors of the TIG-MIG/MAG hybrid welding process on the geometry of the weld bead. An experimental design using the Taguchi methodology (robust design method) was used to conduct the experiments. The experiments were carried out according to an orthogonal matrix with 27 experiments, with three replicates each, totaling 81 test specimens. The factors (MIG/MAG shielding gas type, MIG/MAG voltage, MIG/MAG wire feed, gas flow rate of TIG, electric current intensity of TIG and welding speed) were varied with three levels each. Penetration, heat-affected zone (HAZ), bead width and bead height were the response variables analyzed. The results showed that the penetration was significantly influenced by the MIG/MAG wire feed, MIG/MAG shielding gas type, MIG/MAG voltage and welding speed. The HAZ has been influenced by MIG/MAG voltage, MIG/MAG shielding gas type, welding speed and electric current intensity of TIG. All factors had effects on the width, except the MIG/MAG wire feed. The bead height was significantly influenced by the MIG/MAG wire feed and by the electric current intensity of TIG. Optimizing the process was performed, so that for each output variable, the values of the factors that should be used were indicated, and the optimization was confirmed by welding test specimens.

Highlights

Combining welding processes have been used since the 1970s
This combination has come to be called hybrid welding, which is a technology that consists of combining different types of welding processes, which operate simultaneously in the same weld puddle, i.e., a new process should result from the combination of two conventional processes in which the new process offers the effects of which each process individually is incapable
Many studies have been conducted that combine processes such as those that use electric arc, electron beam, light amplification by stimulated emission of radiation (LASER) and friction

Summary

Introduction

Combining welding processes have been used since the 1970s. This combination has come to be called hybrid welding, which is a technology that consists of combining different types of welding processes, which operate simultaneously in the same weld puddle, i.e., a new process should result from the combination of two (or more) conventional processes in which the new process offers the effects of which each process individually is incapable. Most hybrid welding studies concentrate on combining LASER with some kind of electric arc process, such as: LASER associated with the tungsten inert gas (TIG) [2,3]; LASER with metal inert gas (MIG) or metal active gas (MAG) [4,5,6,7]; LASER with plasma arc welding (PAW); and other configurations. In these cases, different types of LASER (CO2, Nd-YAG, etc.) are used. According to Kanemaru [11], the latter has become a low-cost alternative because the equipment for electric arc welding, compared to that for LASERs, is less expensive

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