The Effect of Gas Metal Arc Welding (GMAW) processes on different welding parameters (original) (raw)
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Gas metal arc welding (GMAW), sometimes referred to by its subtypes metal inert gas (MIG) welding or metal active gas(MAG) welding, is a welding process in which an electric arc forms between a consumable wire electrode and the workpiece metal(s), which heats the workpiece metal(s), causing them to melt, and join.
The Effect of Process Parameter on Weld Depth in Gas metal arc Welding Process
GAS METAL ARC welding (GMAW) is a process that melts and joins metals by heating them with an arc established between a continuously fed filler wire electrode and the metals. The process is used with shielding from an externally supplied gas and without the application of pressure. The American Welding Society refers to the process Gas Metal Arc Welding process to cover arc lengths of electrode and the feeding of the wire are automatically controlled. inert as well as active shield gasses. GMAW is basically a semi-automatic process, in which the Taguchi Technique is used to plan the experiments. The Taguchi method has become an influential tool for improving output during research and development. Taguchi strongly recommends for multiple runs, is to use the signal-to-noise (S/N) ratio for the same steps in the analysis. In this research work of Gas Metal Arc Welding (GMAW) show the effect of Current (A), Voltage (V), Gas Flow rate (Ltr/min) and on weld depth of ST-37 low carbon alloy steel material. In this Experiment we done Experiment by using L9 orthogonal Array to find out weld depth and also perform confirmatory Experiment to find out optimal run set of current, voltage speed and gas flow rate.
International Journal of Engineering and Technology
The Heat-Affected Zone (HAZ) is the region of base metal which has its microstructure altered by welding. Microstructural changes affect the composition of the weldment and need to be controlled since the weld failures are directly related to the microstructure of the Heat affected Zone. This paper is focused on the study of the Gas Metal Arc Welding (GMAW) parameters on the Heat Affected and Weld metal Zone microstructures of industrial low carbon steel (0.20 % C). In order to achieve the aim of the paper, Scan Electron Microscope photos have been used at the Heat Affected and weld metal Zones, some phases are identified. Microstructural analyses of the experimental results of the welded joints confirmed that the welding parameters and heat input are affected the weldment structure in terms of the grain types and character of the structural phase. Keyword-GMAW, HAZ, WM, Wire feed rate, Microstructure. I. INTRODUCTION Gas Metal Arc Welding (GMAW) process is a relatively complex process, but is widely used in industry because of the speed at which joints can be made and the reliability of these joints in service. Microstructure control is crucial to weld quality and prevention of weld failures. The development of techniques to more effectively control microstructure created during welding will have a significant positive impact on product cost and quality [1]-[4]. In a pass of the welding torch material is rapidly heated to the maximum temperature and allowed to cool more slowly by conduction of heat into the bulk of the parent metal. Phase changes can occur depending on the temperature reached. The region next to the fusion zone where microstructural changes have occurred is known as the heat affected zone. Such microstructural changes may affect the mechanical properties of the weld and need to be controlled (e.g. brittle martensite formation) [5]-[7]. In the welding of steels the chemical composition of the base material is directly affected the final structures and mechanical properties of the welded joint. Carbon percentage play a lead role in the ability of welding, low carbon steels exhibited a good welding ability, since they can be generally welded without special precautions using most of the available processes [8]-[10]. Several studies have been conducted to investigate the mechanical behavior and phase transformation of the welded steel joints. Reference [11] presented the effect of heat input on the microstructure and mechanical properties of the heat affected zone of duplex steel. He studied the effect of the heat input on the microstructural changes and the impact properties. Grain growth mechanism of steel welded joint has been investigated as in [12] it has been noticed that the presence of very large grains close to the fusion line and they are oriented along the directions of the heat flow. The present wok aims to study the effect of Gas Metal Arc Welding parameters(interpass temperatures, welding voltage, wire feed Rate and welding speeds) on the Heat Affected Zone (HAZ) and Weld Metal (WM) microstructures of industrial low carbon steel (0.23 % C). II. EXPERIMENTAL WORK 2.1Material The Base Metal used in the experiment was carbon steel (St.52-3N).According to the Egyptian Iron and Steel Co[13].The chemical compositions of the base metal was 0.23 C%, 1.70Mn%,0.60Si%, 0.045P%,0.045S% and 0.011N%. And the mechanical properties was 610N/mm² Tensile Strength, 460 N/mm² Upper Yield Point, 22% elongation and the Vickers hardness is 190 HV. The wire chemical compositions %According to the ESAB Welding Handbook [14]. Was 0.10.23 C%, 1.50 Mn%,0.85Si%. And the mechanical properties was 630N/mm² Tensile Strength, 470 N/mm² r Yield stress ,25% elongation and the Vickers hardness is 200 HV.
Review of Developments in arc welding of metals by gas mixtures
In this review paper we review the developments in the technology of electrical arc welding methods of metals via different types of gas mixtures. The paper is divided into four sections based on process inputs, outputs, control systems and diverse advances in the GMAW process. Section 1 describes advances in powersources,wireelectrodetypes,wirefeedingandshieldinggases.Section 2includes a review of process analysis, sensing, monitoring and control.Section 3 reviews miscellaneousGMAW-relatedimprovedprocessessuchashybridlaser-GMAW, tandem GMAW welding, narrow groove GMAW welding.
A theoretical model for gas metal arc welding and gas tungsten arc
A recently developed theory for predicting arc and electrode properties in gas metal arc welding ͑GMAW͒ has been generalized to include arc-electrode interfaces, variation of surface tension pressure with temperature, Marangoni forces and handling of weld pool development in stationary gas tungsten arc welding ͑GTAW͒. The new theory is a unified treatment of the arc, the anode, and the cathode, and includes a detailed account of sheath effects near the electrodes. The electrodes are included as dynamic entities and the volume of fluid method is used to handle the movement of the free surface of the molten metal at one electrode. Predictions can be made of the formation and shape of the welding droplets as a function of time in GMAW and also of weld pool development in GTAW, accounting for effects of surface tension, inertia, gravity, arc pressure, viscous drag force of the plasma, Marangoni effect and magnetic forces, and also for wire feed rate in GMAW.
EXPERIMENTAL INVESTIGATION OF THE EFFECT OF WELDING PARAMETERS FOR METAL INERT GAS WELDING ON MILD STEEL, 2023
ABSTRACT A good quality of welding focused had been required, when joining two pieces of metals were processed. The changing chemical, physical and thermal properties in order to made joint bond robust and rigid. The problem MIG welding on mild steel improved by controlling process welding parameters such as welding current, voltage, standoff distance and arc speed. The goal of this study was to see how significantly metal inert gas (MIG) welding process parameters affected mechanical properties of A36 mild steel. Method had been used Mathematical model parameters, OA, S/N- ratio, ANOVA, 95% confidence intervals level, Regression analysis for 16 sample. The result had been investigated optimal parameters S/N ratio current 31.37%, arc voltage 18.66%, travel speed 30% and standoff distance 19.97% used S/N ratio. For ANOVA 25% contribution for each factor and regression analysis maximum predicted tensile stress was 288.9MPa, minimum percent improvement for tensile stress was 2.87% maximum value of percent improvement. The percent difference was from 250MPa original material TS and regression analysis of process parameter optimum values combinations were 115, 27.5, 21.125, and 13 for current, voltage, travel speed and standoff distance respectively it was a better hardness and tensile strength. Confirmation tests were also carried out by the welded product tested on UVT machine for design of experiment after optimum parameter determination through destructive testing to proposed optimum parameter settings. The finding of this research work was optimal use of process parameters on weld bed products had been improved tensile stress was widely applicable and valuable in manufacturing industries. S/N ratio voltage was first, current second, travel speed third and standoff distance were the fourth contribution. Keywords: - ANOVA, Design of Experiment, Destructive Test, Metal Inert Gas, Regressions.
STUDY OF MECHANICAL PROPERTIES IN MILD STEEL USING METAL INERT GAS WELDING
The aim of the present study is to show the influence of different input parameters such as welding current, arc voltage and root gap on the mechanical properties during the Metal Inert Gas Welding (MIG) of mild steel 1018 grade. The microstructure, hardness and tensile strength of weld specimen are investigated in this study. The selected three input parameters were varied at three levels. On the analogy, nine experiments were performed based on L9 orthogonal array of Taguchi's methodology, which consist three input parameters. Analysis of variance (ANOVA) was employed to find the levels of significance of input parameters. Root gap has greatest effect on tensile strength followed by welding current and arc voltage. Arc voltage has greatest effect on hardness followed by root gap and welding current. Microstructure of weld metal consists of fine grains of ferrite and pearlite.
The effect of process parameters on penetration in gas metal arc welding processes
Materials & Design, 2007
In this study, the effects of various welding parameters on welding penetration in Erdemir 6842 steel having 2.5 mm thickness welded by robotic gas metal arc welding were investigated. The welding current, arc voltage and welding speed were chosen as variable parameters. The depths of penetration were measured for each specimen after the welding operations and the effects of these parameters on penetration were researched. The welding currents were chosen as 95, 105, 115 A, arc voltages were chosen as 22, 24, and 26 V and the welding speeds were chosen as 40, 60 and 80 cm/min for all experiments. As a result of this study, it was obvious that increasing welding current increased the depth of penetration. In addition, arc voltage is another parameter in incrimination of penetration. However, its effect is not as much as currentÕs. The highest penetration was observed in 60 cm/min welding current.
Heat input in full penetration welds in gas metal arc welding (GMAW)
The International Journal of Advanced Manufacturing Technology, 2013
Weld bead characteristics are metallurgically controlled by heat input, which depends on the welding parameters. However, for numerous welding specialists, an accurate measurement of the current, voltage, and welding speed is enough for preventing unambiguous process specifications. But a comprehensive knowledge of the effect of others parameters, such as plate thickness and the type of pass to be performed (full penetration, root pass, or filler pass), is also required if a less conservative welding procedure is aimed. The goal of the present paper is to increase the ability to control the quality of the welding processes used in production by considering the effect of heat losses through the back side of the weld by radiation for full penetration welding, when developing welding procedure specifications. It is concluded that the thermal efficiency factor and, consequently, the heat input need to be differentiated in the welding specifications for full penetration welding.