The Effect of Switchback Parameters on Root Pass Formation of Butt Welds with Variable Gap

Abstract

Root pass manufacturing in automated welding is still a challenge when the backing plate is not feasible. Using the concept of bead formation in an original way, the GMAW (Gas Metal Arc Welding) switchback technique was assessed against linear movement as a means of facing this challenge. Experimental work was applied, keeping the process parametrization and joint configuration, so that only the switchback parameters were modified, i.e., the stroke lengths and speeds. Thermography was used to estimate the effect of the switchback parameters on bead formation. The results showed the potential of the switchback technique as a means of favoring weld pool control. Surprisingly, the operational gap range is not necessarily larger when switchback is applied. The strong influence of stroke lengths and speeds on the process performance was characterized. In general, the results showed that linear movement leads to larger pools and deeper penetrations, more adequate for gaps with no clearances. Shorter stroke lengths and slower stroke speeds (intermediate pool size) better suit root gaps that are not too wide, while longer stroke lengths and faster stroke speeds (smaller pool size, more easily sustainable) are applicable to larger root gaps.

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

“…For all experimental runs, a root gap of about 1 mm was maintained between weld samples. A preferable joint design was selected based on the initial trial runs to provide better penetration quality and bead formation [30]. Automated welding techniques ensure reliability and also uniformity.…”