Performance of automated machine for different profiles in two-dimensional welding

Abstract

ABSTRACT In this paper, a two-directional automated machine with a controller for flat gas metal arc welding is developed for welding along any complex shape. Consistent and uniform weld bead deposition can be done with this setup. Bond graph was used to model the mechanical system along with electrical/electronic control unit. The system responses (voltage, current, torque) can be obtained from this modeling technique without prior trial before experimentation. The effectiveness of the setup was validated for welding of different closed and opened profiles on low carbon steel workpiece. The welding speed is almost constant except there is a small variation during welding along a curved path. The bead width variations, geometric path of different geometric shapes are measured and validated along with the microstructural characterizations of the base metal, heat-affected zone and welded zone. The micro-hardness of different zones is compared for welding of different profiles.