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Purpose: Since the welding automations have widely been required for industries and engineering, the development of the predicted model has become more important for the increased demands for the automatic welding systems where a poor welding quality becomes apparent if the welding parameters are not controlled. The automated welding system must be modelling and controlling the changes in weld characteristics and produced the output that is in some way related to the change being detected as welding quality. To be acceptable a weld quality must be positioned accurately with respect to the joints, have good appearance with sufficient penetration and reduce low porosity and inclusion content. Design/methodology/approach: To achieve the objectives, two intelligent models involving the use of a neural network algorithm in arc welding process with the help of a numerical analysis program MATLAB have been developed. Findings: The results represented that welding quality was fully capable of quantifying and qualifying the welding faults. Research limitations/implications: Welding parameters in the arc welding process should be well established and categorized for development of the automatic welding system. Furthermore, typical characteristics of welding quality are the bead geometry, composition, microstructure and appearance. However, an intelligent algorithm that predicts the optimal bead geometry and accomplishes the desired mechanical properties of the weldment in the robotic GMA (Gas Metal Arc) welding should be required. The developed algorithm should expand a wide range of material thicknesses and be applicable in all welding position for arc welding process. Furthermore, the model must be available in the form of mathematical equations for the automatic welding system. Practical implications: The neural network models which called BP (Back Propagation) and LM (Levenberg-Marquardt) neural networks to predict optimal welding parameters on the required bead reinforcement area in lab joint in the robotic GMA welding process have been developed. Experimental results have been employed to find the optimal algorithm to predict bead reinforcement area by BP and LM neural networks in lab joint in the robotic GMA welding. The developed intelligent models can be estimated the optimal welding parameters on the desired bead reinforcement area and weld criteria, establish guidelines and criteria for the most effective joint design for the robotic arc welding process. Originality/value: In this study, intelligent models, which employed the neural network algorithms, one of AI (Artificial Intelligence) technologies have been developed to study the effects of welding parameters on bead reinforcement area and to predict the optimal bead reinforcement area for lab joint in the robotic GMA welding process. BP (Back Propagation) and LM (Levenberg-Marquardt) neural network algorithm have been used to develop the intelligent model.

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The gas metal arc (GMA) welding is one of the most widely-used processes in metal joining process that involves the melting and solidification of the joined materials. To solve this problem, we have carried out the sequential experiment based on a Taguchi method and identified the various problems that result from the robotic GMA welding process to characterize the GMA welding process and establish guidelines for the most effective joint design. Also using multiple regression analysis with the help of a standard statistical package program, SPSS, on an IBMcompatible PC, three empirical models (linear, interaction, quadratic model) have been developed for off-line control which studies the influence of welding parameters on bead width and compares their influences on the bead width to check which process parameter is most affecting. These models developed have been employed for the prediction of optimal welding parameters and assisted in the generation of process control algorithms.

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