Optimizing the Parameters of TIG-MIG/MAG Hybrid Welding on the Geometry of Bead Welding Using the Taguchi Method

Abstract

Abstract:The main aim of this work was to evaluate the influence and optimize the factors of the TIG-MIG/MAG hybrid welding process on the geometry of the weld bead. An experimental design using the Taguchi methodology (robust design method) was used to conduct the experiments. The experiments were carried out according to an orthogonal matrix with 27 experiments, with three replicates each, totaling 81 test specimens. The factors (MIG/MAG shielding gas type, MIG/MAG voltage, MIG/MAG wire feed, gas flow rate of TIG, electric current intensity of TIG and welding speed) were varied with three levels each. Penetration, heat-affected zone (HAZ), bead width and bead height were the response variables analyzed. The results showed that the penetration was significantly influenced by the MIG/MAG wire feed, MIG/MAG shielding gas type, MIG/MAG voltage and welding speed. The HAZ has been influenced by MIG/MAG voltage, MIG/MAG shielding gas type, welding speed and electric current intensity of TIG. All factors had effects on the width, except the MIG/MAG wire feed. The bead height was significantly influenced by the MIG/MAG wire feed and by the electric current intensity of TIG. Optimizing the process was performed, so that for each output variable, the values of the factors that should be used were indicated, and the optimization was confirmed by welding test specimens.

Analytic framework on parameter ranking for hybrid TIG MAG arc welding of mild steel

“…Their ranges once arrived at could hold good for the possible arc energy permutations and combinations with reference to the desired process outcome. The model outcome is quite in agreement with the literature of Schneider et al [8] which also lists the similar top few critical parameters with reference to the achieved bead profile and the depth of weld penetration. This analytic framework a step further, accommodates more parameters, total 13, buckets them into three based on their purpose and then ranks them in the order of their critical importance towards the success of the conceived process hybridization.…”

“…The preset shielding gas flow rates arrived through experimentation have been found suitable for all the conducted experimental iterations of the conceived hybrid arc welding process. The CO 2 gas shielding owing to its higher thermal conductivity has been found influential in achieving the depth of weld penetration which is also in agreement with the literature Schneider et al [8].…”

“…This in effect governs the defect free laying of the weldment and directly influences the quality of the weldment. The MAG arc voltage on the other hand doesn’t influence the arc energy and has no impact on the depth of weld penetration but on the profile of the weld being laid which is in line with the literature by Schneider et al [8]. Higher arc voltages are preferred hence for the single pass laying of the welded joints for the effective weld fusion at the joint walls along the length of the weld.…”

“…Both the electrodes are powered through a current bypass from the single power source. For the metal joining of thicker plates wherein the rate of metal deposition carries significant weightage; Meng et al [6], Kanemaru et al [7], and Schneider et al [8] have come up with the other hybrid variant with two separate power sources for the two separate arc welding torches of leading GTAW i.e. Gas Tungsten Arc Welding or TIG i.e.…”

Optimization of the Deposition Rate of Tungsten Inert Gas Mild Steel Using Response Surface Methodology

“…[9] and [10] showed by their works that on selecting input parameters such as welding current, voltage, speed and time against response of ultimate tensile strength of steel, optimization was achieved with the help of Taguchi Method.…”