Parameter Optimization of Gas Metal Arc Welding Process for Welding Dissimilar Steels
Issue:
Volume 8, Issue 1, January 2023
Pages:
1-6
Received:
29 November 2022
Accepted:
17 January 2023
Published:
31 January 2023
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 CO2 as the shielding gas and flux-cored wire of grade 309L as the filler material. The L9 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.
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 stu...
Show More
Finite Element Simulation to Optimize the Mechanical Properties and Deformation of the Bevel Joint of 9.25 mm Thick Aluminum 6061-T6 with only One Pass
Milad Bahrami,
Michel Guillot
Issue:
Volume 8, Issue 1, January 2023
Pages:
7-17
Received:
25 July 2022
Accepted:
18 May 2023
Published:
29 May 2023
Abstract: In industrial settings, it is customary to employ at least a three-passes welding for 9.525 mm-thick welded samples, which results in increased angular distortion and longitudinal/transversal deformation. This study outlines the optimized welding parameters for a butt-welded joint V groove with a 60-degree bevel angle and a 2.5 mm root face, utilizing a single pass, on a 9.525 mm thick sample. The present investigation involved the development of a 3D computational model to examine the thermal characteristics and distortion distribution during the process of gas metal arc welding of the aluminium alloy 6061-T6. The present paper employed the Taguchi methodology to compute the thermal behaviour technique using orthogonal arrays, a well-established Design of Experiments (DOE) approach for finite element analysis (FEA). Additionally, an artificial neural network (ANN) model was employed to forecast distortion and stress. The study produced 3D surface graphs and contour plots to clarify the correlation between welding parameters, stress, and distortion. Following the determination of optimized parameters through finite element analysis (FEA), experimental tests were conducted to compare and validate the FEA outcomes. The present investigation has employed welding parameters, namely arc voltage (v), arc travel speed (mm/s), current (A), gun angle (degree), distance between the nozzle and weld (mm), and root gap (mm).
Abstract: In industrial settings, it is customary to employ at least a three-passes welding for 9.525 mm-thick welded samples, which results in increased angular distortion and longitudinal/transversal deformation. This study outlines the optimized welding parameters for a butt-welded joint V groove with a 60-degree bevel angle and a 2.5 mm root face, utiliz...
Show More
