InternationalJournalofTechnologyandManagement ISSN19279000|Vol.2No.1,pp.

18(2013)

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Application of Taguchi based Design of Experiments to Fusion Arc Weld Processes: A Review
S. P. Kondapalli1*, S. R. Chalamalasetti2 and N. R. Damera3 1 ANITS, India 2 Andhra University, India 3 Centurion University of Technology & Management, India
Abstract
Design of Experiment (DOE) is one of the extensively used methods for experimental study of many manufacturing processes in engineering. DOE is a statistical approach in which a mathematical model is developed through experimental runs. Thus, possible output can be predicted based on the input parameters of the experimental setup. The present study reviews current literature on DOE techniques that have been employed for various welding processes with particular emphasis on the application of Taguchi method on fusion arc welding processes namely, gas tungsten arc welding and plasma arc welding. Keywords: Design of experiment, DOE, Mathematical model, Taguchi method, welding.

1. Introduction
Design of Experiment (DOE) is an experimental or analytical method that is commonly used to statistically signify the relationship between input parameters to output responses, where by a systematic way of planning of experiments, collection and analysis of data is executed. DOE has wide applications especially in the field of science and engineering for the purpose of process optimization and development, process management and validation tests. A mathematical model has been developed by (Avinash and Vinod, 2007) using analysis techniques such as ANOVA and regression analysis whereby the mathematical model shows the relationship between the input parameters and the output responses (Montgomery, 1991). Among the most prominently used DOE techniques are Response Surface Methodology (RSM) with Central Composite Design (CCD), Taguchis method and Factorial Design. In DOE, synergy between mathematical and statistical techniques such as Regression, Analysis of Variance (ANOVA), Non-Linear Optimization and Desirability functions help to optimize the quality characteristics considered under a cost effective process. ANOVA helps to identify the effect of each factor versus the objective function (Wang et al., 2007). Experimental design was first introduced in 1920s by R. A. Fischer who developed the basic principles of factorial design and the associated data analysis known as ANOVA during research in improving the yield of agricultural crops (Alagumurthi et al., 2006).

2. Taguchi Method
Since the last four decades, there were limitations when conventional experimental design techniques were applied to industrial experimentation. Dr. Genichi Taguchi, a Japanese engineer, developed a new method that is known as orthogonal array design, which adds a new dimension to conventional experimental design. Taguchis DOEs are denoted by Labc where La the orthogonal arrays of variables or design matrix, b the levels of variables and c numbers of variables. Taguchi method is a broadly accepted method of DOE which has proven in producing high quality products at subsequently low cost.

*Correspondingauthor:kspanits@gmail.com

Kondapalli,ChalamalasettiandDamera2013|ApplicationofTaguchibasedDesign

This method is regularly used in automobile, electronics and other processing industries. The objective of the Taguchi method is to determine the optimum settings of input parameters, neglecting the variation caused by uncontrollable factors or noise factors (Sivarao et al., 2010). Factor here refers to an input variable whereby the state can be controlled during the experiment. Taguchi method, (Juang and Tarng, 2002; Wu and Chang, 2004), a systematic application in design and analysis of experiments, is used for designing and improving product quality. It has become a powerful tool for improving productivity during research and development so that high quality products can be produced at reduced costs. However, the original Taguchi method was designed to optimize a single performance characteristic. Furthermore, optimization of multiple performance characteristics is much more complicated than optimization of a single performance characteristic (Lin and Ho, 2003; Fung, 2003; Tarng et al., 2002; Lin et al., 2004; Huang and Liao, 2003). Although similar to DOE, the Taguchi design only conducts the balanced (orthogonal) experimental combinations, which makes the Taguchi design even more effective than a fractional factorial design. By using the Taguchi technique, industries are able to greatly reduce product development cycle time for both design and production thus reducing costs and increasing profit (Julie et al., 2007). Taguchi proposed that engineering optimization of a process or product should be carried out in a three-step approach: system design, parameter design and tolerance design. In system design, the engineer applies scientific and engineering knowledge to produce a basic functional prototype design. The objective of the parameter design (Ross, 1988) is to optimize the settings of the process parameter values for improving performance characteristics and to identify the product parameter values under the optimal process parameter values. The steps included in the Taguchi parameter design are: selecting the proper Orthogonal Array (OA) according to the number of controllable factors (parameters); running experiments based on the OA; analyzing data; identifying the optimum condition; and conducting confirmation runs with the optimal levels of all the parameters (Julie et al., 2007). The main effects indicate the general trend of influence of each

parameter. Knowledge of the contribution of individual parameters is the key to decide the nature of the control to be established on a production process. ANOVA is the statistical treatment most commonly applied to the results of the experiments to determine the percentage contribution of each parameter against a stated level of confidence (Julie et al., 2007) Taguchi suggests (Roy, 1990) two different routes for carrying out the complete analysis. In the standard approach, the results of a single run or the average of repetitive runs are processed through the main effect and ANOVA (raw data analysis). The second approach, which Taguchi strongly recommends for multiple runs is to use the Signalto-Noise (S/N) ratio for the same steps in the analysis. The Grey system theory proposed by (Deng, 1989) has been proven to be useful for dealing with poor, incomplete and uncertain information. The Grey relational analysis can be used to solve complicated interrelationships among multiple performance characteristics effectively (Lin, 2003). By this analysis, a Grey relational grade is obtained to evaluate the multiple performance characteristics. As a result, optimization of the complicated multiple performance characteristics can be converted into optimization of a single Grey relational grade. An advantage of the Taguchi method is that it emphasizes a mean performance characteristic value close to the target value rather than a value within certain specific limits, thus improving the product quality. Additionally, Taguchi's method for experimental design is straightforward and easy to apply to many engineering situations, making it a powerful yet simple tool. It can be used to quickly narrow the scope of a research project or to identify problems in a manufacturing process from data already in existence (Fraley et al., 2006). It is probably unfortunate that the important concepts advocated by Taguchi have been overshadowed by controversy associated with his approach to modeling and data analysis. There have been many papers and several books explaining, reviewing, or criticizing Taguchis ideas (Nair, 1992; Parks, 2001). Most of these, however, have not adequately captured the diverse views on the topic and their underlying rationale. In particular, the Taguchi methodology has not

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InternationalJournalofTechnologyandManagement|Vol.2No.1,pp18

been well represented in statistical journals. These considerations led to a published panel discussion by a group of practitioners and researchers (Nair, 1992). The topics covered include the importance of variation reduction, the use of noise factors, the role of interactions and selection of quality characteristics, S/N ratios, experimental strategy, dynamic systems, and applications. Panelists provided comments on topics on which they have worked or with which they had practical experience. Their comments were organized into sections to give readers a balanced picture of the different views on each topic. In this panel discussion, Shin Taguchi proclaimed Pure science strives to discover the casual relationship and to understand the mechanics of how things happen. Engineering, however, strives to achieve the result needed to satisfy the customer. In the same paper, Box among others, declared his profound disagreement with this claim. Jeff Wu, one of the panelists, pointed out that the S/N ratio was an objective of the analysis. Raghu Kacker suggested that it should be kept in mind that Taguchi method is not an universal approach (Nair, 1992).The role of interactions has been debated vigorously since Taguchis approach to experimental design for robust products and processes became known in United States. A perception persists in the statistical literature that Taguchis approach assumes that interactions are absent and hence the method is unscientific. The presence of interactions implies that a much larger number of experiments would be needed to study the same number of control factors (Parks, 2001).Understanding contributions to noise factors is very difficult. Knowledge of the noise factors and their behavior is an important prerequisite to an efficient experiment. If the noise factor exhibits variation and further experimental detail is required using an outer array configuration, then understanding of the range of variation of the noise factor will be required to select the factor levels. Often noise factor cannot be controlled during the experimentation (Nair, 1992). De Mast (2004) compared three methodologies (Shainin system, Taguchi methods, Six Sigma) for quality improvement and concluded that Taguchi methodology falls short in the exploration phase for which it provides only limited guidance and the

focus on picking optimal settings (as opposed to gaining insight in the system) is debatable. The main disadvantage of the Taguchi method is that the results obtained are only relative and do not exactly indicate what parameter has the highest effect on the performance characteristic value. Also, since orthogonal arrays do not test all variable combinations, this method should not be used with all relationships between all variables. Taguchi method has been criticized in the literature for its difficulty in accounting for interactions between parameters. Another limitation is that the Taguchi methods are offline, and therefore inappropriate for a dynamically changing process such as a simulation study. Furthermore, since the Taguchi methods deal with designing quality rather than correcting for poor quality, they are applied most effectively at early stages of process development (Unitek Miyachi Group, 1999).

3. Application of DOE to Fusion Arc Welding Processes

In the present day fabrication industry, welding has become one of the major manufacturing processes frequently used in all types of works. Quality of a weld joint is influenced by welding input parameters that are to be controlled to establish a proper weld. The input parameters selected vary with the type of welding process, thickness and type of base material used. In order to establish the correct combination of input weld parameters trail experiments are to be performed which consume a lot of time and increase manufacturing cost. Hence statistical techniques are utilized to avoid trial experiments and reduce the manufacturing cost. For that purpose experiments are to be conducted in a sequential manner according to the type of statistical technique selected. Statistical techniques like Factorial Method, Response Surface Method and Taguchi Method are adopted in Design of Experiments to optimize the required output parameters. A thorough review on application of Taguchi Method on various fusion Arc welding processes is presented in the following sections. 3.1. Gas Tungsten Arc Welding (GTAW) Tarng and Yang (1998) used Taguchi method to optimize weld bead geometry of GTAW process. Five input parameters and three levels were chosen

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Kondapalli,ChalamalasettiandDamera2013|ApplicationofTaguchibasedDesign

for each parameter. Experiments were conducted as per L18 orthogonal array. Arc gap, polarity ratio, welding speed, filler speed and welding current were chosen as input parameters and Front height, front width, back height and back width were chosen as output parameters. Kumar et al. (2009) studied the effect of welding parameters on mechanical properties and optimization of pulsed TIG welding of AL-Mg-Si alloy. Experiments were carried out using Taguchis L8 (27) orthogonal array. Peak current, base current, welding speed and pulse frequency were chosen as input parameters whereas mechanical properties like tensile strength, impact strength, hardness were chosen as output parameters. Esme et al. (2009) investigated multi- response optimization of TIG welding process for an optimal parametric combination to yield favorable bead geometry of weld joints using Grey relational analysis and Taguchi method. L16 (44) orthogonal array was used to perform the experiments. Kishore et al (2010) analysed the defects in Gas Shielded Arc Welding of AISI 1040 steel and Aluminum Alloy AA 6351 using Taguchi method. L8 orthogonal array was used to perform the experiments. The defects in TIG process were analyzed and output responses were measured using Ultrasonic testing. Kumar et al. (2011) investigated the enhancement of mechanical properties and effective optimization of pulsed GTAW process parameters on aluminum alloy 6061 using sinusoidal AC wave with argon plus helium gas mixtures. Modified Taguchi Method (MTM) was employed to formulate experimental layout and to study effects of process parameter optimization on mechanical properties of the weld joints. Microstructural characterization of weld joint was carried out to understand the structural property correlation with process parameters. Ahmadi and Ebrahimi (2012) studied the effect of each TIG welding parameter on the welds penetration depth. Optimal parameters were determined using the Taguchi method with L9 (34) orthogonal array. SiO2 and TiO2 oxide powders were used to investigate the effect of activating flux on the TIG weld penetration depth and mechanical properties of 316L austenitic stainless steel. The experimental results showed that activating flux aided TIG welding has increased the weld penetration, tending to reduce the width

of the weld bead. The SiO2 flux produced the most noticeable effect. Furthermore, the welded joint presented better tensile strength and hardness. Kumar and Datta (2012) examined the optimal mechanical properties of Ti-6Al-4V titanium alloy with pulsed gas tungsten arc welding (GTAW) process. The welding characteristics were considered together in the selection of process parameters using various argon plus helium mixtures as a shielding gas with sinusoidal AC wave and modified Taguchi method was used to analyze the effect of each welding process parameter on mechanical properties. Sathish et al. (2012) studied the welding of dissimilar metals, carbon steel and stainless steel pipes which find wide application in the field of chemical, oil and petroleum industries. GTAW (Gas Tungsten Arc Welding) process is commonly applied to a wide range of metals which use a nonconsumable tungsten electrode. Carbon steel pipe specimen (A106 Grade B) and stainless steel pipe specimen (A312 TP 316L) of 6 ID, thickness 7.11mm and length 150 mm each were selected. Taguchi method is used to formulate the experimental layout to rank the welding input parameters which affects the quality of the weld and is influenced by the parameters like gas flow rate followed by current and bevel angle. The welds are subjected to tensile testing to find qualitative properties. Heat Inputs for the welded specimens, which influence the mechanical and metallurgical properties of the weld, were calculated. Non-destructive test of the welded specimens was carried out using Radiography test method. Also susceptibility to inter granular corrosion of the welded specimens along with its microstructure is studied for varying heat inputs. The percentage contribution of each parameter and prediction of tensile strength is found by analysis of variance (ANOVA) technique. The experimental tests show that high tensile strength is obtained for intermediate values. In addition, Yousefieh et al. (2012) implemented Taguchi design method with L9 orthogonal array to optimize the pulsed current gas tungsten arc welding parameters for the hardness and the toughness of super duplex stainless steel (SDSS, UNS S32760) welds. In this regard, the hardness and the toughness were considered as performance characteristics. Pulse current, background current,

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InternationalJournalofTechnologyandManagement|Vol.2No.1,pp18

% on time, and pulse frequency were chosen as main parameters. Each parameter was varied at three different levels. As a result of pooled analysis of variance, the pulse current is found to be the most significant factor for both the hardness and the toughness of SDSS welds by percentage contribution of 71.81 for hardness and 78.18 for toughness. The % on time (21.99%) and the background current (17.81%) had also the next most significant effect on the hardness and the toughness, respectively. The optimum conditions within the selected parameter values for hardness were found as the first level of pulse current (100 A), third level of background current (70 A), first level of % on time (40%), and first level of pulse frequency (1 Hz), while they were found as the second level of pulse current (120 A), second level of background current (60 A), second level of % on time (60%), and third level of pulse frequency (5 Hz) for toughness. The Taguchi method was found to be a promising tool to obtain the optimum conditions for such studies. Rastkerdar et al. (2012) used Taguchi method as a design of experiment (DOE) technique to optimize the pulsed current gas tungsten arc welding (GTAW) parameters for improved pitting corrosion resistance of AA5083-H18 aluminum alloy welds. A L9 (34) orthogonal array of the Taguchi design was used, which involves nine experiments for four parameters: peak current (P), base current (B), percent pulse-on time (T), and pulse frequency (F) with three levels was used. Pitting corrosion resistance in 3.5 wt.% NaCl solution was evaluated by anodic polarization tests at room temperature and calculating the width of the passive region (Epit). Analysis of variance (ANOVA) was performed on the measured data and S/N (signal to noise) ratios. The "bigger is better" was selected as the quality characteristic (QC). The optimum conditions were found as 170 A, 85 A, 40%, and 6 Hz for P, B, T, and F factors, respectively. The study showed that the percent pulse-on time has the highest influence on the pitting corrosion resistance (50.48%) followed by pulse frequency (28.62%), peak current (11.05%) and base current (9.86%). The range of optimum Epit at optimum conditions with a confidence level of 90% was predicted to be between 174.81 and 177.74 mVSCE. Under optimum conditions, the confirmation test was carried out, and the experimental value of Epit of 176 mVSCE was in agreement with the

predicted value from the Taguchi model. In this regard, the model can be effectively used to predict the Epit of pulsed current gas tungsten arc welded joints. 3.2. Plasma Arc Welding (PAW) Zhang and Niu (2000) studied the influence of welding current, arc voltage, welding speed, wire feed rate and magnitude of ion gas flow on front melting width, back melting width and weld reinforcement of Alternating Current Plasma Arc Welding process using Artificial Neural Network (ANN)-Back Propagation algorithm. Orthogonalising design matrix was used to perform the experiments. Chi and Hsu (2001) developed an intelligent decision support system for Plasma Arc Welding based on fuzzy Radial Basis Function (RBF) neural network. Experiments were conducted based on Taguchi method. Hsiao et al. (2008) studied the optimal parameters process of Plasma Arc Welding (PAW) by the Taguchi method with Grey relational analysis. Torch standoff, welding current, welding speed, and plasma gas flow rate (Argon) were chosen as input variables and welding groove root penetration, welding groove width, front-side undercut were measured as output parameters. Taguchi orthogonal array is employed for the experiment and different levels were considered among the major welding parameters. After the experiment was completed, the S/N ratio and Grey relation of each evaluation indicator of the welding groove was computed respectively and then major parameters were assessed through ANOVA for selection of optimal parameters and prediction of the welding quality. Taguchi orthogonal array of L18 was used. Utilization of the optimal welding parameter combination enhances a significant improvement of the Grey relation. Yildiz and Gur (2011) investigated the alloying of FeCrC powder on the surface of AISI 1030 steel with FeCrC powder having 70 % Cr ratio with the Plasma Transferred Arc Welding Method. In the coating process performed with the Plasma Transferred Arc Welding Method, N2 gas at 1-35% ratio was added to the shielding gas. The abrasive wear behavior of AISI 1030 substrate material whose surface was coated with high Cr in different atmospheres and the coating layer with high Cr were investigated under 5-10 N load and at 10-20 meter distances. The effect of wear loss on

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Kondapalli,ChalamalasettiandDamera2013|ApplicationofTaguchibasedDesign

the lowest wear behavior, which is a most important criterion in determining the wear behavior, was optimized with the lowest-the best control characteristics of the Taguchi method and the results were analyzed with graphical methods. Furthermore, Ismail and Taha (2011) employed Taguchi method to optimize the processing parameters in the plasma arc surface hardening process. The processing parameters evaluated are arc current, scanning velocity and carbon content of steel. In addition, other significant effects such as the relation between processing parameters are also investigated. An orthogonal array, signal-tonoise (S/N) ratio and ANOVA are employed to investigate the effects of these processing parameters. Through this study, not only the hardened depth increased and surface roughness improved, but also the parameters that significantly affect the hardening performance are identified.

4. Conclusions
Taguchi is interested in finding a "robust" solution to the experimental problem. It seeks an answer

that is insensitive to factor variations and noise. It doesn't predict the best combination of factors to achieve desired goals. Taguchi analysis can provide definitive information if there is only one response but it does not deal with situations where a number of responses are to be optimized. The time required for conducting experiments using Taguchi method is almost half that needed for the RSM. From the earlier works on fusion arc welding processes like GTAW and PAW, it is understood that many researchers concentrated on Taguchi based DOE for predicting the weld quality characteristics like weld bead geometry, grain size, hardness and tensile strength. In almost all the cases the researchers used Taguchi method with Artificial Neural Network (ANN) and Grey Relational Analysis in their works. However few works have been reported out using Genetic Algorithms (GA) and Swarm Optimization (PSO). One may concentrate on Taguchi based DOE with GA & PSO. In most of the works maximum four factor, five levels have been chosen; one may go for more factors and higher levels for better accuracy.

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