Optimization and Influence of GMAW Parameters for Weld Geometrical and Mechanical Properties Using the Taguchi Method and Variance Analysis

Abstract

Gas metal arc welding is one of the arc fusion processes that is widely used in industry due to its high efficiency. The correct selection of the input parameters has direct influence on the weld quality and, with the control of those parameters, it is possible to reduce the amount of weld material, improve its properties and then increase the productivity of the process. This study intends to take a group of weld parameters and submit them to the optimization by the Taguchi Method and check the influence of those through a Variance Analysis (ANOVA). An L9 orthogonal array gathered three parameters (weld voltage, weld speed and weld torch angle) into three levels, then, with all combinations set and performed, the macrography and the transversal tensile strength test provided, respectively, the geometrical and the mechanical properties. The signal-to-noise ratios enable the optimization and the ANOVA provided the influence of the input parameters on the response parameters. The weld speed appeared as the most influent parameter for the weld geometry, contributing 63.54% to reinforcement, 66.36% to width and 66.94% to penetration, and the weld torch angle the most influent to the ultimate transversal tensile strength (41.39%). The optimum levels to the reinforcement are 22.4 [V], 400 [mm/min] and 30 [°], to the width 22.4 [V], 300 [mm/min], 0 [°], to the penetration 23.3 [V], 400 [mm/min], 0 [°] and, lastly, to the ultimate transversal tensile strength 24.1 [V], 200 [mm/min], 15 [°]. The Taguchi method showed to be suitable for this kind of problem and giving an efficient experiment design and good results.
 Keywords: Taguchi method, Optimization, GMAW

Grey-Based Taguchi Multiobjective Optimization and Artificial Intelligence-Based Prediction of Dissimilar Gas Metal Arc Welding Process Performance

“…The fundamental understanding is that the mass transfer processes, involved in the deposition of molten metal on a weld surface, have a direct relationship with weld bead geometry [32]. The weld geometry is assessed through bead width, depth of penetration, and reinforcement (Figure 3).…”

Study the Influence of Welding Parameters by Taguchi’s Design on the Mechanical Properties of Welded Mild Steel (S235jr)

“…In order to lower the expenses, there are numerous techniques for optimizing the process, such as the Design of Experiments (DoE), Taguchi's design, and ANOVA analysis. Taguchi's design was proposed by several researchers for welding process optimization due to the fact that it uses an orthogonal array experimentation design with a minimum number of runs or experiments [9]. It is widely used to optimize engineering and manufacturing processes.…”

“…It compares the mean of the response or the results (signal) to the standard deviation, which is the noise. The ratio depends on the characteristics and quality of the product and the desired output, whether to maximize (higher is better), minimize (lower is better), or nominally target the target (nominal is better) [10,11,12].…”

“…However, to achieve the optimal welding parameters for more effective welds has been manufacturers endeavor always. The mechanical properties of welding is an important aspect for the consistenly of such welding products [9,13].…”

Optimization of Welding Process Parameter for Gap Response in Aluminum GMAW Using Taguchi Method

“…Achebo 등은 일반강의 GMAW에서 최대 용접부 인장 강도를 도 출할 수 있는 용접전류와 용접전압, 용접 시간, 용접 속 도를 최적화하였다 21) . Casarini 등은 일반강의 GMAW 에서 용접전압과 용접 속도, 용접 토치 각도를 변화시 켜 용접부 형상 및 최대 인장 강도를 확보할 수 있는 최적의 용접 조건을 도출하였다 22) . Kim 등은 stainless steel의 GMAW에서 비드 폭과 비드 높이, 용입 깊이, 비드 크기와 같은 용접부 형상에 대해서 와이어 직경과 용접 전류, 용접 전압, 용접 속도를 최적화하였 다 23) .…”