Abstract
With increasing requirements of higher strength to low weight ratio materials, high-strength low-alloy (HSLA) steel has achieved higher commercial importance. Plasma arc welding has the capability to join metals without edge preparation, weldment in a single pass and minimum angular distortion. Due to these embedded capabilities, plasma arc welding is preferred over conventional joining processes for HSLA steel applications involving part thickness greater than 3 mm. The quality of plasma arc-welded joints is highly dependent on input process parameters. This paper aims to develop empirical models for the prediction of weld bead geometry including front bead height, back bead height, front bead width, and back bead width. A series of tests were conducted to investigate the effect of four input process parameters including current, voltage, welding speed, and plasma gas flow rate on weld bead geometry using a face-centered central composite design. The confirmation experiments and ANOVA results validated the models within 95 % accuracy. Current was found to be the most influential factor affecting the weld bead geometry followed by speed. Furthermore, current and speed and speed and gas flow rates were identified as most influencing interaction factors. The innovation in this research is the empirical modeling of weld bead geometry for HSLA using plasma arc welding.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Xu WH, Lin SB, Fan CL, Yang CL (2014) Evaluation on microstructure and mechanical properties of high-strength low-alloy steel joints with oscillating arc narrow gap GMA welding. Int J Adv Manuf Technol 75(9–12):1439–1446
Connor LP, O'Brien RL (1991) Welding handbook: welding processes (Vol. 2). American Welding Society, USA
Wu CS, Wang L, Ren WJ, Zhang XY (2014) Plasma arc welding: process, sensing, control and modeling. J Manufac Process 16(1):74–85
Keanini RG, Rubinsky B (1990) Plasma-arc welding under normal and zero gravity. Weld J 69(6):41–50
Teker T, Özdemir N (2012) Weldability and joining characteristics of AISI 430/AISI 1040 steels using keyhole plasma arc welding. Int J Adv Manuf Technol 63(1–4):117–128
Feng Y, Luo Z, Liu Z, Li Y, Luo Y, Huang Y (2015) Keyhole gas tungsten arc welding of AISI 316L stainless steel. Mater Des 85:24–31
Migiakis K, Daniolos N, Papadimitriou GD (2010) Plasma keyhole welding of UNS S32760 super duplex stainless steel: microstructure and mechanical properties. Mater Manuf Process 25(7):598–605
Prasad KS, Rao CS, Rao DN (2012) Study on factors effecting weld pool geometry of pulsed current micro plasma arc welded AISI 304L austenitic stainless steel sheets using statistical approach. J Miner Mater Charact Eng 11:790–799
Prasad KS, Rao CS, Rao DN (2011) Prediction of weld pool geometry in pulsed current micro plasma arc welding of SS304L stainless steel sheets. Int Trans J Eng Manag Appl Sci Technol 2(3):325–336
Juang S, Tarng Y (2002) Process parameter selection for optimizing the weld pool geometry in the tungsten inert gas welding of stainless steel. J Mater Process Technol 122:33–37
Iqbal A, Khan SM, Mukhtar HS, (2011) ANN assisted prediction of weld bead geometry in gas tungsten arc welding of HSLA steels. In Proceedings of the World Congress on Engineering WCE 2011, July 6–8, 2011, London, UK
Prasad KS, Chalamalasetti SR, Damera NR (2015) Application of grey relational analysis for optimizing weld bead geometry parameters of pulsed current micro plasma arc welded Inconel 625 sheets. Int J Adv Manuf Technol 78(1–4):625–632
Prasad KS, Ch SR, Rao N (2010) Prediction of weld quality in plasma arc welding using statistical approach. AIJSTPME 3(4):29–35
Al-Faruk A, Hasib A, Ahmed N, Das UK (2010) Prediction of weld bead geometry and penetration in electric arc welding using artificial neural networks. Int J Mech Mechatronics Eng 10:19–24
Kumar V (2011) Modeling of weld bead geometry and shape relationships in submerged arc welding using developed fluxes. Jordan J Mech Ind Eng 5(5):461–470
Lalitnarayan K, Sarcar MMM, Rao KM, Kameswaran K (2011) Prediction of weld bead geometry for CO2 welding process by multiple regression analysis. Int J Math Sci Comput 1(1):52–57
Liu Z, Wu CS, Gao J (2013) Vision-based observation of keyhole geometry in plasma arc welding. Int J Therm Sci 63:38–45
Siva K, Murugan N, Logesh R (2009) Optimization of weld bead geometry in plasma transferred arc hardfaced austenitic stainless steel plates using genetic algorithm. Int J Adv Manuf Technol 41(1–2):24–30
Zhang G, Wu CS, Liu X (2015) Single vision system for simultaneous observation of keyhole and weld pool in plasma arc welding. J Mater Process Technol 215:71–78
Murugan N, Gunaraj V (2005) Prediction and control of weld bead geometry and shape relationships in submerged arc welding of pipes. J Mater Process Technol 168:478–487
Wu CS, Jia CB, Chen MA (2010) A control system for keyhole plasma arc welding of stainless steel plates with medium thickness. Weld J 89(11):225–231
Narang H, Singh U, Mahapatra M, Jha P (2011) Prediction of the weld pool geometry of TIG arc welding by using fuzzy logic controller. Int J Eng Sci Technol 3:77–85
Shoeb M, Parvez M, Kumari P (2013) Effect of MIG welding input process parameters on weld bead geometry on HSLA steel. Int J Eng Sci Technol 5:200–212
Benyounis K, Olabi A, Hashmi M (2005) Effect of laser welding parameters on the heat input and weld-bead profile. J Mater Process Technol 164:978–985
Goyal V, Ghosh P, Saini J (2009) Analytical studies on thermal behaviour and geometry of weld pool in pulsed current gas metal arc welding. J Mater Process Technol 209:1318–1336
Zhang GJ, Yan ZH, Lin WU (2006) Visual sensing of weld pool in variable polarity TIG welding of aluminium alloy. Trans Nonferrous Metals Soc China 16(3):522–526
Azam M, Jahanzaib M, Wasim A, Hussain S (2015) Surface roughness modeling using RSM for HSLA steel by coated carbide tools. Int J Adv Manuf Technol 78(5–8):1031–1041
Montgomery DC (2001) Design and analysis of experiments 5th edition. John Wiley and Sons, New York
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Jahanzaib, M., Hussain, S., Wasim, A. et al. Modeling of weld bead geometry on HSLA steel using response surface methodology. Int J Adv Manuf Technol 89, 2087–2098 (2017). https://doi.org/10.1007/s00170-016-9213-0
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-016-9213-0