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ISSN: 2455-5703
Abstract
Nowadays, the customer satisfaction is the major responsibilities and duties of the organizations management. In this research
paper we find the best optimized welding joints with process parameters such as: welding current, welding voltage and gas flow
rate for the best tensile strength and micro-hardness of the welding joints. Taguchi method which reduces the variation in process
through design of experiments has been used. In this study presents an efficient method for determining the optimal Gas Metal Arc
Welding parameters for increasing the weld ability of Stainless Steel 202 & Stainless Steel 304 under varying condition through
the use of Taguchi parameter process. The study shows that the optimum parameters for tensile strength are found when Welding
Voltage is at 18 Volts, Welding Current at 50 Amps and Gas Flow Rate at 15 L/min and optimum parameters for hardness are
found when Gas Flow Rate is at 15 L/min, Welding Current at 75 Amps and Welding Voltage at 18 Volts. From ANOVA it is
found that welding parameters significantly affects the weld quality of Stainless Steel 202 and Stainless Steel 304.
Keywords- Welding, Welding Joint, Taguchi Approach
I. INTRODUCTION
The process of welding is a procedure of joining similar and dissimilar metals with the use of filler material usually in form of a
rod and with or without the application of pressure. During welding procedure, metals or thermoplastics are welded. In simple
terms, welding involves the use of four components which are: the metals, a heat source, filler metal, and some kind of shield from
the air. The metals are heated to their melting point while being shielded from the air, and then a filler metal is added to the heated
area to produce a single piece of metal. The welding process is broadly utilized as a part of domestic and industrial purposes, for
example, joining of railway lines, ship building, roadways, bridges and machinery’s parts etc. The methodologies of brazing and
soldering are similar to the welding process. Arc welding is one of the most famous process among the welding processes. This
kind of welding was firstly seen in the late part of the 19th century.
The Metal Inert Gas welding is an arc welding process where solid consumable wire electrode is fed with the help of
welding torch between work pieces. Joining the two materials properly, or in this process electric arc are forms between work piece
and wire electrode, which heat and melts the metals and join them. A shielding gas is also used which feeds through with the
welding torch or gun to protect the weld area from environmental conditions, such gases are argon, helium, carbon dioxide, nitrogen
etc. Mostly CO2 is widely used in MIG welding, because it is least expensive and used for deeper penetration etc. This type of
welding process can be automatic and semi-automatic. For MIG welding thickness of metal should be more than 3mm. The most
commonly power source of MIG welding are constant voltage and direct current are used. There are some following metals are
used for MIG welding such as, Mild steel, Stainless steel and Aluminium etc.
1) Mild steel is easily weld and have less amount of problems.
2) Aluminium is difficult to weld with MIG welding due to oxides are deposited during welding process. But easily weld with
TIG welding.
3) Stainless steel is easily welded but requires more skill than mild steel. MIG welding can be easily done using ferrous and non-
ferrous metals and has great role in industries due to its flexibility, and higher deposition rates etc.
critical. They studied the defects in Gas Shielding Arc welding (TIG and MIG) of AISI 1040 were done. Taguchi techniques were
used to describe the orthogonal array. The data obtained were checked on ANOVA. The data was collected using the Ultrasonic
Testing in which angle beam testing was used for testing the weldments. The results of the specimens showed the presence of
defects such as LOP, Blowhole, LOF and cracks. H.T Zhang et al. [5] in this literature lap joints of two dissimilar material welding
was done between 1 mm thick magnesium and aluminium alloy plates by using MIG welding in which zinc foil was used as a
barrier layer and a crack free joint was obtained. The tensile strength was done on the lap joint and the value obtained was 64
MPA. Satyaduttsinh P. Chavda et al. [6] this research paper presented the impact of MIG welding parameters such as wire feed
rate, gas flow rate, welding current etc on the weld pool geometry and weld strength of Medium Carbon Steel material during the
welding process. DOE method was used to optimize the welding parameters to find the best parameters combinations. Experimental
based Taguchi techniques were used to acquire the date and analysis of Variance (ANOVA) and an orthogonal array were used to
study the welding characteristics. Gejendhiran S. et al. [7] this review article investigated the influence of welding parameters on
the mechanical properties MIG welding and GAs Tungsten Arc Welding (GTAW). The review paper shows the effect of various
welding parameters such as shielding gas, welding speed, current, voltage etc on the mechanical properties of welding.
IV. MATERIAL
The materials that were used in the research paper were Stainless Steel 202 and Stainless Steel 304 with dimension (100X75X75
mm3).
Table 1: Chemical composition of Stainless Steel 202
Element Fe Cr Mn Ni Si N C P S
% contribution 68 17-19 7.50-10 4-6 ≤ 1 ≤ 0.25 ≤ 0.15 ≤ 0.060 ≤ 0.030
Table 2: Chemical composition of Stainless Steel 304
Element Fe Cr Mn Ni Si C P S
% contribution Balance 17.5-20 ≤ 2 8-11 ≤ 1 ≤ 0.08 ≤ 0.045 ≤ 0.030
Table 6: Response table of Tensile strength versus current, voltage and gas flow rate
LEVEL WELDING CURRENT WELDING VOLTAGE GAS FLOW RATE
1. 53.69 48.99 53.43
2. 50.77 50.91 51.14
3. 50.01 54.57 49.90
DELTA 3.68 5.58 3.52
RANK 2 1 3
Table 7: Optimum parameters levels for the tensile strength
RANK 1 Welding Voltage Level 3 18 Volts
RANK 2 Welding Current Level 1 50 Amps
RANK 3 Gas Flow Rate Level 1 15 L/min
Table 8: Response Table for S/N Ratio of Hardness on weld areas
LEVEL WELDING CURRENT WELDING VOLTAGE GAS FLOW RATE
1. 52.35 52.89 54.24
2. 54.31 53.10 54.17
3. 52.99 53.66 51.24
DELTA 1.96 0.77 3.00
RANK 2 3 1
Table 9: Optimum parameters levels for the hardness at weld area
RANK 1 Gas Flow Rate Level 1 15 L/min
RANK 2 Welding Current Level 2 75 Amps
RANK 3 Welding Voltage Level 3 18 Volts
VII. CONCLUSIONS
The study, by using Taguchi technique, found that in the case of tensile strength, welding voltage has the most significant effect
followed by welding current and gas flow rate. In case of hardness, it is found that gas flow rate has the most significant effect
followed by welding current and welding voltage. Taguchi method is very useful in designing of the high quality products. With
the help of human judgments, we cannot control the various design parameters settings and if we do then it is very time and cost
consuming.
REFERENCES
[1] Taichi Murakami, Kazuhiro Nakata, Hongjun Tong and Masao Ushio. 2003. "Dissimilar Metal Joining of Aluminium to steel by MIG Arc Brazing Using
Flux Cored Wire" ISIJ International, Vol. 43 (2003), No.10, pp.1596-1602
[2] M. Marya, S. Marya , D. Priem. 2005. "On the characteristics of Electromagnetic welds between Aluminium and other Metals and Alloys." Welding in the
World, Vol. 49
[3] H.T Zhang, J.C. Feng, P. He, H. Hackl. 2006. "Interfacial microstructure and mechanical properties of aluminium-zinc-coated steel joints made by a modifies
metal inert gas welding-brazing process: Elsevier Journals
[4] K.Kishore, P.V.Gopal Krishna, K. Veladri and Syed Qasim Ali. 2010. "Analysis of defects in gas shielded welding of AISI1040 Steel using Taguchi Method."
ARPN Journal Engineering and Applied Sciences
[5] H.T. Zhang, J.Q. Song. 2011. "Microstructural evolution of aluminium/magnesium lap joints welded using MIG process with zinc foil as an interlayer."
Elsevier Journals.
[6] Satyaduttsinh P. Chavda, Jayesh V. Desai, Tushar M. Patel. 2014. "A review on optimization of MIG Welding parameters using Taguchi's DOE Method."
Vandana Publications, Volume-4, Issue-1.
[7] Gejendhiran S., Satheesh Kumar K V, Dr. Sivakumar A. 2014. “A study of welding parameters on mechanical properties of Gas Metal Arc Welding and Gas
Tungsten Arc Welding: A Review." International Journal of Advanced Engineering Research and Studies E-ISSN2249-8974.