Parametric optimization of weld reinforcements using response surface methodology optimization process

S.O Sada

doi:10.4314/jasem.v22i8.31

Abstract

This study analyzes the effect of the process parameters such current, voltage, gas-flow rate and weld speed on a 10mm thick mild steel plate for minimum reinforcement height using the tungsten arc welding process. With the use of design expert, response surface methodology was applied in constructing a design matrix, analyzing the data and obtaining a mathematical model. The minimised weld reinforcement of 0.016mm was observed at a weld current setting of (200amp), voltage (18volt), gas flow rate (22L/min) and speed (4.5mm/sec) with a desirability value of 0.983. The analysis of variance (ANOVA) test performed to ascertain the adequacy of the model, showed that the welding current and gas flow rate had the most significant effect on the weld reinforcement. Keyword: Gas Tungsten Arc Weld, Weld Reinforcements, Response Surface Methodology

Highlights

Welding is an indispensable method of joining metals, the construction and manufacturing industries all make use of one joining process or another
The quality of a weld can be achieved by meeting an acceptable bead geometry, a quality requirement which is greatly influenced by various process parameters involved in the process (Ravikumar and Vijian 2017)
Inadequate weld bead geometry contributes to the failure of welded structure (Tarang and Yang, 1998).The bead width of a weld is the maximum width of the deposited weld metal

Summary

Introduction

Welding is an indispensable method of joining metals, the construction and manufacturing industries all make use of one joining process or another. The quality of a welded joints is greatly affected by numerous weld imperfections These weld imperfections can be classified into two: weld discontinuities and surface irregularities (Yuewiet al 2017). The quality of a weld can be achieved by meeting an acceptable bead geometry (the bead width and height/reinforcement height), a quality requirement which is greatly influenced by various process parameters involved in the process (Ravikumar and Vijian 2017). The reinforcement height is the bead height above the surface of the plate, it influences the strength of the weld and wire feed rate. (Kang et al 2003), explained that the selection of significant process input parameters is very necessary to obtain accurate bead geometry, which represents the strength and quality of the weld. The objective of this study is to minimize the weld reinforcement in a 10mm mild steel welded plate using the response surface methodology

Objectives

Methods

Results

Conclusion