Experimental investigation on cladding with metal cored wire using GMAW process and parametric optimization

Abstract

Cladding is widely used in manufacturing industries for the production of pressure vessel by depositing thick layer of filler material for providing corrosion resistant-surface. The use of metal cored wire in gas metal arc welding (GMAW) process is popular due to its higher deposition rate and productivity. This work investigates the effect of process parameters on the deposition of cladding layer with ER 309L metal core wire (as filler material) on a corrosion resistant material (IS 2062). The welding parameters viz., wire feed rate (WFR), voltage (V), welding speed (S) and nozzle to plate distance (NTD) are employed as process parameters while penetration (P), bead width (W), reinforcement (R), weld penetration shape factor (WPSF) and weld reinforcement form factor (WRFF) as welding responses. The predictive model developed for P, W, R, WPSF, and WRFF using the response surface methodology (RSM) approach is found adequate at 95% confidence interval. The validation results for the developed model results in a model accuracy (MA) of 92.82%, 96.34%, 91.47% 88.98% and 87.75% for model P, W, R, WPSF, and WRFF respectively and it shows higher predictability and accuracy. The process parameters are optimized simultaneously with integrated optimization approach using RSM with Jaya algorithm and obtain optimal solution in less than 20 number of iterations. The minimum fitness value obtained as 1.3008 at an optimal parameter setting of WFR = 12 m min−1, V = 26 V, S = 280 mm min−1, NTD = 10 mm. The validation result at the optimal parameter setting results in an improvement of 6.45%, 11.29%, 13.58%, 16.07%, 15.38% is noted for P, W, R, WPSF, and WRFF respectively.

Microstructural characterization martensitic stainless-steel coatings deposited by laser metal deposition

“…Karadeniz et al observed that as welding speed increases, penetration increases to a maximum point where higher speeds result in a decrease in penetration [104]. Two parameter optimization studies for GMAW using RSM confirm this behavior [105,106].…”

Welding investigation of Hastelloy C-276 and parametric optimization using integrated MRA-TLBO algorithm during A-TIG process

“…Additional evidence of the effectiveness of HTS in optimising the goal function was provided by 3D surface plots for DOP. Ashish et al [16] deposited a cladding layer with ER309L filler material using a GMAW process on mild steel (2062 grade) plate. It was concluded that the RSM-JAYA optimisation procedure had given an optimal result.Bishub et al [17] utilised L27 Box-Behnken experimental design, to investigate multiple optimisation of weld bead characteristics during the GTAW welding of INCONEL 825 plate of 2.5 mm thickness.…”

Use of DC Motor Control in Development of Pipe Welding Technology by Using the GMAW Process for Variation of Welding Nozzle Movement

“…Previous research on GMAW welding showed that variations in current and voltage with 1mm diameter filler affected the mechanical properties of hardness and tensile strength of commercial steel and it was found that changes in physical properties resulted in changes in the strength of the welded product [1] [4]. It was also found that welding speed as a process parameter influenced the optimization of welding results [9] by deposition of a cladding layer with ER 309L metal core wire in GMAW welding [6]. In addition, GMAW welding speed parameters using the Taguchi method are used to optimize the tensile strength of the welding results [11].…”