Metal Inert Gas Welding Process Research Articles

Residual Stress Prediction during TIG and MIG Welding Process of Steel - A Review

In this study, a forensic review of residual stress predictions and its impact on welded joints especially the steel pipes during the Tungsten inert gas welding and metal inert gas welding processes were reviewed. It was established that in the case of MIG welding, the effect of residual stress can be reduced after treatment. In the case of TIG welding process, increase in current will lead to deformation and residual stresses. Estimating the residual stress is a challenging task. It is common to predict residual stress using a notch stress intensity factor, a numerical simulation approach coupled with a thermal-mechanical finite element model. Thus, adequate design in welding parameters will help in the optimization of the process to achieve a safe and reliable welded joint during TIG and MIG welding process.

A comparative study on weld-bead geometry of austenitic stainless-steel produced by cold metal transfer welding and pulse metal inert gas welding process

In recent years, weld cladding has become an emerging technique for the surface modification of carbon steel, which has various industrial applications such as chemical, marine, mining, agriculture, and power generation. In this research, cold metal transfer (CMT) welding and pulse metal inert gas (MIG) welding are utilized to study the weld-clad bead of 308L stainless steel over low-carbon steel. To examine the mechanical and wear characteristics of CMT weld-clad samples, welding speed (3, 4, 5, and 6 mm/s) was used as the input process parameter, while current (175 A), nozzle to workpiece distance (10 mm), and shielding gas flow rate (15 l/min) were kept constant. Microstructural analysis of weld bead samples was done through optical microscopy and field emission scanning electron microscopy. With an increase in welding speed, the microhardness and wear properties of the clad surface were improved. The CMT-clad surface had significant improvements in mechanical, wear properties, and lower residual stresses due to low dilution and lesser heat input.

Application of grey-based fuzzy logic algorithm in MIG welding-A case study

In this article, a grey-based fuzzy logic algorithm was proposed as a soft computing method to optimize the metal inert gas (MIG) welding process parameters during the joining of stainless steel (AISI) 304. In welding, welding process parameters play a significant role to evaluate the weld quality i.e. mechanical properties. Input parameters selected for examination referred to as welding current, voltage, wire feed speed and gas flow rate were optimized. The grey-based fuzzy logic algorithm was used to obtain a grey fuzzy reasoning grade (GFRG) and it was observed from result that experiment number seven have the highest value of MPCI. In this experimental work arc voltage play a major role on the determination of MPCI and it was also observed that the grey-based fuzzy method is very helpful for the continuous enhancement of the product quality and on fractrography mode of fracture was ductile observed.

Development of an Artificial Intelligence-Based System for Predicting Weld Bead Geometry

The prediction of the weld bead geometry parameters is an important aspect of welding processes due to it is related to the strength of the welded joint. This research focuses on using statistical design techniques and a deep learning neural network to predict the weld bead shape parameters of shielded metal arc welding (SMAW), metal inert gas (MIG), and tungsten inert gas (TIG) welding processes. With the statistical design techniques, experiments were carried out to obtain the data for generating the regression models. Establishing mathematical models that shows the relationship between welding process parameters and weld bead size is significant for practical applications. The mathematical model enables the determination of the weld bead size when setting specific welding process parameters. In this research, experimental research results were obtained to build mathematical models showing the relationship between welding process parameters and weld bead geometries for SMAW, MIG, and TIG welding processes. The research results serve as the basis for establishing predictive systems or optimizing welding process parameters. With deep learning neural network techniques, we developed an artificial intelligence-based system for predicting complicated relations between the welding process parameters and the weld bead size. Both a regression model and the deep learning model result in a good correlation between the welding process parameters and the weld bead geometry.

Evaluation of strength in stainless steel weld joints using ball indentation technique

In the present study, strength variations across the type 316LN stainless steel weld joints processed by advanced hot wire tungsten inert gas, activated tungsten inert gas, and hybrid laser metal inert gas welding processes were evaluated using automated ball indentation technique. The secondary dendrite arm spacing (SDAS) associated with welding heat input and welding thermal cycles strongly influenced the strength properties across the weld joints. The strength properties were lower at 823 K compared to 298 K because of thermally activated deformations. The hybrid laser metal inert gas welding process exhibited significantly narrower weld and higher strength in the weld and heat-affected zone due to finer SDAS and grain size, respectively, than the other weld joints.

Effect of Single and Double Pulse MIG Welding Process Parameters on Microstructure and Properties of Aluminium Alloy

Lightweight aluminium alloys are widely used in many industries due to their advantageous mechanical properties. As welding is a popular method for joining aluminium alloy sheets, it is important to understand how the welding process affects the alloy’s performance. Here, we investigated the influence of various operating parameters during pulsed metal inert gas (MIG) welding of thin aluminium alloy plates on the input energy and metallurgical microstructure of the weld. A series of welding tests were performed using surface welding of AA6061 aluminium alloy plates under conditions of a single strong-pulse, single weak-pulse, or double pulse. The morphology, metallurgical structure, and hardness of the welds produced using the different welding parameters were then examined. We observed that increasing the welding speed and the arc duration of low-energy pulses can reduce the heat input. Lower heat input is advantageous as it results in a higher cooling rate of the welding pool and a smaller average grain size of the weld structure. In addition, increasing the welding speed increased the hardness of the weld. Double pulsed MIG welding showed the best overall weld performance and is recommended for improving the quality of aluminium alloy bonding.

Numerical simulation for determination of temperature field and residual stress of stainless steel butt joints with and without clamping

Many welded structures are fabricated from stainless steels because these steels have good mechanical properties and good corrosion resistance. It is necessary to predict the residual stress after welding in order to evaluate the performance of the welded joint. In this paper, the butt welded joint of AISI 316L stainless steel plates is studied. The Metal Inert Gas (MIG) welding process is selected for this material. A SYSWELD software based on the Finite Element Method (FEM) is used to determine the temperature field and residual stresses of two stainless steel plates. The welding simulation includes a sequential coupled thermomechanical analysis. The elemental generation and death technique is utilized to simulate metal deposition in welding. The double ellipsoidal heat source model is used for the heat input of the MIG welding process. The temperature distribution for various time steps at some important points is presented. Cooling times and cooling rates over a temperature range of 800 oC to 500 oC at these points are determined. The residual stress distribution in the longitudinal and transverse direction in two cases with and without clamping is obtained and compared. Obtained results show that: the temperature field in the case of clamping is the same as in the case of no clamping; only the longitudinal stress and transverse stress components are important, the other stress components are not important; the longitudinal stress at the middle of weld line is very high; the transverse stress in the case of clamping is greatly increased, so it is necessary to limit clamping to reduce residual stress after welding

Experimental and finite element analysis of temperature distribution in 409 M ferritic stainless steel by TIG, MIG and SMAW welding processes

ABSTRACTIn this study, three different arc welding processes, namely tungsten inert gas (TIG), metal inert gas (MIG) and shielded metal arc welding (SMAW) processes, are used to weld 409 M ferritic stainless steel. K-type thermocouples are located in the area of heat-affected zone by drilling blind holes in a plate at a distance of 3 mm and 7 mm from the weld line, revealing the contours of the temperature distribution of the weld. The experimental results are compared with the results of simulations using ANSYS by Goldak heat source model. The temperature is experimentally measured in the heat-affected region with the help of a thermocouple. The temperature distribution profile by the finite element method using ANSYS is compared with the experimental temperature distribution profile with the heat source. The experimental and simulation results for TIG, MIG and SMAW welding processes have been found to be excellent.

EFFECT OF DIFFERENT MIG WELDING MODES ON HARD-FACING OF INCONEL 718 ON 321 STAINLESS STEEL

In this study, the metal inert gas (MIG) welding process is taken to deposit the Inconel 718 material on 321 stainless steel. Various modes like the DC, DC-pulsed, and DC-wave-pulsed modes in MIG welding are used for depositing Inconel 718. The primary parameters such as the welding current (90–120 A) and speed (150–350 mm/min) are varied within the range for making the layer deposition over 321 stainless steel. After performing the layer deposition, the dilution, contact angle, and peak temperature are analyzed to find the optimal MIG welding mode. From the macrograph, very low dilution (7.44%) is identified for the DC mode. The most inferior contact angle ([Formula: see text]) of 49° was measured for the DC-wave-pulsed mode. The simulation work predicted a peak temperature of 2800°C for the DC mode. Considerable microstructure changes have occurred at the weld deposition (dendritic structure) and HAZ (grain coarsening) for all the three modes. At the top, interface, and HAZ locations, the microhardness obtained from the DC-pulsed mode is in between those of the DC and DC-wave-pulsed modes. Overall, the DC-pulsed mode is qualified for making the metal deposition and further work. For 50% overlap, defect-free 2-mm-thick layer depositions are made on the 321 stainless steel surfaces.

PENGARUH FREKUENSI GETARAN TERHADAP SIFAT FISIS DAN MEKANIK PADA SAMBUNGAN LAS MIG ALUMINIUM PADUAN AA 6061-T6

AA 6061-T6 aluminium alloy is one of the 6xxx series that is widely used in engineering, especially automotive, aircraft, piping, and shipbuilding industries because it has many advantages. Despite AA 6061-T6 has a relatively good weldability, the strength of the weld joints is lower compared to its AA6061-T6 base metal. Therefore, this study aims to improve mechanical properties of metal inert gas (MIG) welded AA 6061-T6 aluminium alloy plates such as hardness and tensile strength by introducing engineering vibration during welding at a frequency of 100 Hz. The MIG welding process was conducted using current (I), voltage (E) and welding speed (v) of 120 Ampere, 20 Volt and 12 mm/minute respectively with filler metal used was ER5356. Results showed that the ultimate tensile strength of the weld joints increased under vibrational treatment with the tensile strength achieved 172.02 MPa which was 49% higher compared to conventional weld joint. The higher strength of the vibrated weld joints could be linked to the weld microstructure which consisted of fine grained equiaxed-dendritic structures.

Optimization of Synchropulsed MIG Welding Process Parameters for Welding of AW 5083 Sheets

Metal inert gas (MIG) welding is one of the processes most commonly used for joining metals, especially for joining aluminum and its alloys. The application of a pulsed current in an electric arc allows better controllability of the molten droplets and the arc transition, which subsequently leads to welds with characteristic flaky joints of better quality. In this paper, the optimization of parameters for welding aluminum alloys using the synchropulse welding process is investigated. By observing the input variables that have the greatest influence on the change in appearance of the welding current characteristics (delta wire feed from 0.1 to 6.0 m/min, frequency F from 0.5 to 3 Hz, duty cycle from 10% to 90%), it is possible to perform an optimization to achieve the desired output values. The output variables of the experiments are defined as insufficient/excessive throat thickness (mm), depth of penetration (mm), and weld width (mm); and for the desired quality of the welded joint the most acceptable range of its values is selected, the numerical optimization implementation. The experiment has shown that the delta wire feed has the greatest effect on the observed properties, while the influence of frequency F and duty cycle is somewhat smaller, but the factors responsible for the observed output properties are still significant. From all this, it is possible to select specific values of these input variables to define the best possible observed properties and to determine the characteristics of the defined mathematical models.

Observation of Microstructure and Mechanical Properties in Heat Affected Zone of As-Welded Carbon Steel by Using Plasma MIG Welding Process

Plasma MIG welding is a hybrid welding process that combines two welding methods of conventional metal inert gas (MIG) welding with plasma arc welding. This study investigates the effect of plasma and plasma current values on the microstructure and microhardness properties of welded carbon steel plates. It was found that utilization of the plasma has resulted in a refined microstructure in the heat affected zones (HAZ), and a decrease in microhardness values as compared to conventional MIG welds. This potentially increases the ductility of the plasma MIG weldments. Furthermore, decreasing the plasma currents would result in the decrease of microhardness and grain sizes, thus further increasing the ductility of the welds.

Tensile strength of welded joints in low carbon steel using metal inert gas (MIG) welding

The development of technology that has penetrated the industrial sector is very rapid. Many industrial fields apply the use of MIG (Metal Inert Gas) welding for various jobs in steel construction, especially mild carbon steel. MIG welding has good welding results and fast welding time efficiency. The purpose of this study is to analyze the tensile strength of welded joints on low carbon steel using MIG welding. The experimental method used in this study is to perform MIG welding on low-carbon steel plate profiles. The welded carbon steel is used as a test specimen and is formed according to the ASTM E8-M standard. Tensile testing is performed using a Shimadzu UH-300 kN type tensile testing machine. From this study, the tensile strength value of the test specimen welded by MIG (Metal Inert Gas) welding is higher than the tensile strength of the parent metal (low carbon steel), so this shows the strength of the weld joint. The average value of tensile strength on the test specimen is (σ) 507.40 N/mm2 and average strain (ɛ) 3.63%. The MIG welding process, between the base metal and filler metal with different chemical compositions, can cause mixing and a dilution effect of two compositions.

Comparative Research of Microstructure and Mechanical Properties of Stainless and Structural Steel Dissimilar Welds.

The present study utilized a metal inert gas welding (MIG) to make a dissimilar weld of stainless steel AISI 304, 314, 316L, 420 grades and a standard structural steel S355MC. It refers to a weld joining two materials from different alloy systems commonly used in heat exchangers, pressure vessels, and power plant systems. Obviously, maintaining the integrity of such welds is of paramount importance to the safety issues. Therefore, detailed microscopic and experimental studies were performed to evaluate the reliability of these welds. The microscopic analysis did not reveal any presence of weld defects such as porosity or cracks, which ensured that MIG process parameters were properly selected. The performance of dissimilar welds was assessed by hardness and tensile tests. The hardness profiles revealed differences between austenitic and martensitic steel welds that later showed extremely high values in the heat-affected zone (HAZ), which caused fractures in this zone during tensile test. The welds of all austenitic steel grades withstood the tensile test, showing an average tensile strength of 472 MPa with fractures observed in the base metal zone. It made clear that the use of a filler rod 308LSI is suitable only for the austenitic stainless and structural steel dissimilar welds and not appropriate for martensitic-structural steel welds. The achieved results revealed that the higher hardness of the martensitic phase in the HAZ of AISI 420 is closely related with the formation of untempered coarse martensitic structure and higher carbon content.

Investigational study and microstructural comparison of MIG welding process for with and without activated flux

In this study, the impact of the various oxide fluxes in activated metal inert gas (MIG) welding of SS316 has been studied. Three distinct fluxes ZnO, Al2O3, and SiO2have been used for welding of 5 mm thick plate. The process parameters such as welding voltage, welding current, and activated flux have been considered as input parameters whereas responses are Ultimate Tensile Strength (UTS), Depth of Penetration, as well as Microstructure have been analyzed. Welding experimentation has been carried out using MINITAB 19 software using Taguchi approach, with L9 orthogonal array. The Microstructural analysis results with the use of SEM were found to have a better-ordered grain structure and improved the structure, surface, and pattern of the weld with flux than those produced without flux. This study aims to study the impact of oxide fluxes on welding parameters and welding morphology and to study the microstructure characteristics of with and without flux welding using Scanning Electron Microscope results.

Investigating the Effect of Metal Inert Gas Welding Parameters on AA10119 Mild Steel Quality by Taguchi Method

In welding, the quality of welded joints is greatly influenced by the welding process parameters. Thus, in order to achieve a good weld quality, there is exigency to select the right welding process parameters. The focus of this study is to investigate the effect of Metal Inert Gas (MIG) welding process parameters; welding current, welding voltage and welding speed on the tensile strength of mild steel AA10119 welded plates. The experiment was designed using Taguchi’s L9 orthogonal array with three levels. Kaierda MIG MAG Inverter CO2 Welder Model E-180 welding machine was used to conduct the experiments with three repetitions. From the analysis carried out by applying Taguchi’s method, the result shows that the welding speed and welding current have the most significant influence on tensile strength of the weld and an optimum parameter setting of A3B2C2 was suggested; welding current 240 A, welding voltage 25 V and welding speed 0.010 m/s. The mean tensile strength at this optimal setting A3B2C2 was predicted to be 442 N/mm2.

Analysis of Tensile Strength of Inert Gas Metal Welding on Aluminum 5083 with Variations in Argon Gas Current and Discharge

In the technology industry, metal raw materials such as steel and aluminum have an important role in the production process, as so far there is no metal that cannot be joined by welding. Metal Inert Gas (MIG) welding method is a gas arc welding that uses a welding wire as well as an electrode. In the Metal Inert Gas (MIG) welding process, the heat from this welding process is generated by a welding arc formed between the wire electrode and the workpiece. The purpose of this study was to determine the tensile strength of the welding results in the connection process with Metal Inert Gas (MIG) against aluminum (Al) 5083 series 6 mm thick, the welding was carried out with various current strength treatments, namely 120 A, 130 A, 140 A. and Argon gas discharge 5 lt/minute, 10 lt/minute, 15 lt/minute in each welding process. This research is useful to know and understand about the analysis of the welding process on aluminum 5083 with a thickness of 6 mm with Metal Inert Gas (MIG) welding process using vertical (3 grove) welding techniques. The method used in this study is the analytical method, which is a method for testing by adding different treatments of current and discharge variations of Argon gas during the welding process of the specimen, so that different welding strengths will be obtained in each specimen.

Application of MIG Welding Process of Mild Steel Wire in Additive Manufacturing

The purpose of this study is to investigate the forming characteristics of single-pass Metal Inert Gas (MIG) welding wire for multi-layer additive manufacturing parts. Influences of arc current, arc voltage, arc distances, welding speed, wire feed speed, temperatures and heat input on layer formation were analyzed. The deposition of material by MIG process is controlled by a robot (ABB) controller for constructing walls of rectangular box shape. The samples were measured with a microhardness testing and tensile testing onto the welded bead created by the additive manufacturing technique. It was found that the mechanical properties of microhardness values are between 151.70 to 155.80 HV and the tensile strength values are between 472.71 to 491.12 MPa according to transverse and longitudinal sections of the specimens.

Mechanical and microstructural behaviour of weldment of two low alloy steels using MIG

In industrial applications, various types of materials are used and strength of weldment of two alloys is a major cause of interest among engineering community. In this study P11 and P22 steels were welded using ER −70 - S6 wire electrode with metal inert gas (MIG) welding process using CO2 as shielding gas. The strength of the weldment was tested by impact testing, Hardness by Micro Vicker hardness and Microstructure of weldment before and after the failure was examined using a metallurgical microscope. The results of experiments performed on the specimen on impact testing machine showed that the impact energy of welded specimen was 49 J in Charpy impact test, whereas, that of parent metal P11 was 48 J and for P22, it was 64 J. The result of impact test shows that the impact energy of weldment of P11 and P22 lies between the impact energy of parent alloys. The microhardness at Heat affected zone (HAZ) was highest and at base metal, it was lowest whereas, at weldment microhardness value lies in between microhardness value of base metal and HAZ. Specimen were heat treated in a furnace in an air environment at 700, 800 and 900 °C for 2 h and subsequently cooled in the furnace. The results of impact test show increased strength of weldment after post weld heat treatment (PWHT) at all temperatures however, the strength was found to decrease with increase in temperature of PWHTs.

Modeling the predictive values of ultimate tensile strength in welded joint by response surface methodology

Abstract Strength always remains the prime requirement of any produced products, which normally explicate the capability of the products to sustain stress into it. Ultimate tensile strength is principally used to clarify the maximum values of stress, which can be resist by any product or material entity before breaking. Accordingly, study is conducted to verify the methodological way of determining the predictive values of ultimate tensile strength in welded joint. Response surface methodology is used in present study to grace decision results. In present study, the Metal Inert Gas (MIG) welding process is experimentally performed in mild steel plate specimens by considering three distinguish values of welding current, voltage and plate thickness. The objective of the study is to enroll the predictive equation to assists in deriving the elevated values of ultimate strength of the welded joint. The primary objective of present study is to demonstrate the utilization of competent structure of Response surface methodology under the dimensional arena of welding process. Here, the authors devised equation, which competently possess caliber to define the predicted values of ultimate tensile strength for the precise values of process parameter. The same assist in precisely understanding the behavior of ultimate tensile strength (dependent variable) under the influence of independent variables i.e. welding current, voltage and plate thickness. Response surface methodology is used and experiments based on Box-Behnken Design are performed in present study. The work is supported by MINITAB software for generating graphs and originating driving equation between response and process parameters. The predictive values are determined based on multiple regression equation and compared with actual experimental values to demonstrate capability and applicability.