Abstract
Welding is a method of joining similar and dissimilar metals through the use of coalescence. GMAW is a semi-mechanized, fully-mechanized, or automatic process that is widely used in fabrication. GMAW is expected to evolve further to allow for better arc control, bead contour control, deposition control, and higher productivity. The goal of this study is to enhance welding process variables for dissimilar steel metal joints made of duplex stainless steel (DSS) to ASTM/UNS S32205 and erosional steel CORTEN-A to ASTM A242. Such a dissimilar metal joint finds use in the transportation sector, particularly in the construction of rail cars. The square butt joint between two 2 mm-thick sheets was investigated using the gas metal arc welding (GMAW) process with CO<sub>2</sub> as the shielding gas and flux-cored wire of grade 309L as the filler material. The L<sub>9</sub> Taguchi array was used to optimize the tensile strength of the resulting weld joint, which was the desired quality characteristic. GMAW process parameters such as voltage, wire feed rate, and welding speed are optimized at three levels. Using ANOVA, the effects of each factor have been studied. It was found that the ideal set of parameters exists and that the voltage is the most crucial factor. A confirmation test was performed to validate the results, and it was accompanied by a figure and tables.
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