Estimation and Comparison of Welding Performances Using MRA and GMDH in P-GMAW for SS 316L Material

2018 ◽  
Author(s):  
Rudreshi Addamani ◽  
Ravindra Holalu Venkatadas ◽  
Ugrasen Gonchikar ◽  
Y. D. Chethan
Keyword(s):  
Process Parameters ◽  
Arc Welding ◽  
Gas Flow ◽  
Gas Metal Arc Welding ◽  
Thin Sheet ◽  
Welding Process ◽  
Industrial Applications ◽  
Metal Arc Welding ◽  
Welding Processes ◽  
Gmaw Welding

The Pulsed Gas Metal Arc Welding (P-GMAW) process is used in high-technology industrial applications and it is one of the most significant arc welding processes. The quality, productivity and cost of welding will be affected by the P-GMAW welding input process parameters and are considered to the most important factors. It is necessary to determine the input and output relationship of the welding processes in order to understand and control the P-GMAW welding process parameters. P-GMAW is widely used process, especially in thin sheet metal industries. It offers an improvement in quality and productivity over regular Gas Metal Arc Welding (GMAW). The process enables stable spray transfer with low mean current and low net heat input. This paper describes the estimation and comparison of welding process parameters viz., current, gas flow rate and wire feed rate on ultimate tensile strength, yield strength, percentage of elongation and hardness. Experiments have been performed based on Taguchi’s L27 standard orthogonal array. Estimation of welding performances have been carried out using sophisticated mathematical models viz., MRA and GMDH, and, compared. The GMDH algorithm is designed to learn the process by training the algorithm with the experimental data. Three different criterion functions, viz., regularity, unbiased and combined criterions were considered for estimation in GMDH. Different GMDH models can be obtained by varying the percentage of data in the training set and the best model can be selected from these, viz., 50%, 62.5% and 75%. Estimation and comparison of welding performances were carried out using MRA and GMDH techniques.

Modeling and Optimization of Gas Metal Arc Welding (GMAW) Process

2012 ◽  
pp. 339-367
Author(s):  
R. Venkata Rao
Keyword(s):  
Process Parameters ◽  
Arc Welding ◽  
Gas Metal Arc Welding ◽  
Welding Process ◽  
Optimization Methods ◽  
Optimization Techniques ◽  
Modeling And Optimization ◽  
Metal Arc Welding ◽  
Process Output ◽  
Set Up

Weld quality is greatly affected by the operating process parameters in the gas metal arc welding (GMAW) process. The quality of the welded material can be evaluated by many characteristics, such as bead geometric parameters, deposition efficiency, weld strength, weld distortion, et cetera. These characteristics are controlled by a number of welding process parameters, and it is important to set up proper process parameters to attain good quality. Various optimization methods can be applied to define the desired process output parameters through developing mathematical models to specify the relationship between the input parameters and output parameters. The method capable of accurate prediction of welding process output parameters would be valuable for rapid development of welding procedures and for developing control algorithms in automated welding applications. This chapter presents the details of various techniques used for modeling and optimization of GMAW process parameters. The optimization methods covered in this chapter are appropriate for modeling and optimizing the GMAW process. It is found that there is high level of interest in the adaptation of RSM and ANN techniques to predict responses and to optimize the GMAW process. Combining two optimization techniques, such as GA and RSM, would reveal good results for finding out the optimal welding conditions. Furthermore, efforts are required to apply advanced optimization techniques to find out the optimal parameters for GMAW process at which the process could be considered safe and more economical.

Effect of DE-GMAW (Double Electroda Gas Metal Arc Welding)’s Resistance on Mechanical and Physical Properties of Aluminium Alloy Weld

2018 ◽  
Vol 789 ◽  
pp. 64-68
Author(s):  
Yustiasih Purwaningrum ◽  
Medilla Kusriyanto ◽  
Rudi Kurniawan ◽  
Okto Akbar Rizky
Keyword(s):  
Physical Properties ◽  
Aluminium Alloy ◽  
Arc Welding ◽  
Gas Metal Arc Welding ◽  
Welding Process ◽  
Weld Metals ◽  
Metal Arc Welding ◽  
Mechanical And Physical Properties ◽  
Double Electrode ◽  
Gmaw Welding

This paper presented the effect of DE-GMAW (Double electrode gas metal arc welding)resistance on mechanical and physical properties of aluminium alloywelded. DE-GMAWis amethodof welding process that use two electrode. A non consumable torch is added to bypass the current inorder to reduce the heat input. The variation resistance used were 15Ω, 30Ω and 45Ω. Universaltesting machine and Vickers microhardness were used to measured mechanical properties of weldmetals with respect to strength and hardness. The microstructure was investigated by microscopeoptic with 100 x magnification. The grain size of weld metals with resistance value 30Ω is finer than15Ω and 45Ω. Dye penetrant test shows DE-GMAW welding machine that made have goodperformance because it can produce welding joint without surface crack. The results show thatresistance values optimum to DE-GMAW welding on aluminium alloy 5051 with 4 mm thickness is30Ω. It can be seen from the tensile test that shows the highest tensile strength is found in the DEGMAWwelding with resistance values 30Ω.

A study on sustainability assessment of welding processes

2019 ◽  
Vol 234 (3) ◽  
pp. 501-512 ◽  
Author(s):  
Jaber Jamal ◽  
Basil Darras ◽  
Hossam Kishawy
Keyword(s):  
Arc Welding ◽  
Social Impact ◽  
Sustainability Assessment ◽  
Gas Metal Arc Welding ◽  
Welding Process ◽  
Friction Stir ◽  
Gas Tungsten Arc ◽  
Metal Arc Welding ◽  
Sustainability Assessments ◽  
Welding Processes

The concept of “sustainability” has recently risen to take the old concept of going “green” further. This article presents general methodologies for sustainability assessments. These were then adapted to measure and assess the sustainability of welding processes through building a complete framework, to determine the best welding process for a particular application. To apply this methodology, data about the welding processes would be collected and segregated into four categories: environmental impact, economic impact, social impact, and physical performance. The performance of each category would then be aggregated into a single sustainability score. To demonstrate the capability of this methodology, case studies of three different welding processes were performed. Friction stir welding obtained the highest overall sustainability score compared to gas tungsten arc welding and gas metal arc welding.

scholarly journals CARACTERIZAÇÃO E ESTUDO COMPARATIVO ENTRE OS PROCESSOS GMAW E SMAW NA SOLDAGEM DE AÇO ESTRUTURAL ASTM A606, APLICADOS NA CONSTRUÇÃO CIVIL E MINERAÇÃO

2021 ◽  
Vol 9 (209) ◽  
pp. 1-32
Author(s):  
Vinícius de Albuquerque Santos
Keyword(s):  
Arc Welding ◽  
Mechanical Test ◽  
Gas Metal Arc Welding ◽  
Mining Industry ◽  
Welding Process ◽  
Mechanical Tests ◽  
Metal Arc Welding ◽  
Starting Point ◽  
American Society ◽  
Welding Processes

The article makes a general study of Gas Metal Arc Welding (GMAW) and Solid Metal Arc Welding (SMAW) welding, welded on structural steel under the American Society for Testing and Materials (ASTM) A606. The welding process and its applicability in the construction and mining industry are presented. This work has as a starting point, the concepts of welding processes, thermal aspects involved, metallurgy, Thermally Affected Zone (ZTA), recurrent discontinuities and the result of mechanical tests. The material was welded to specimens in both processes. The mechanical test was evaluated, the anchoring in the bending of the material in the weld bead and characteristics of the weld quality. It was found that the material welded with SMAW showed greater tensile strength. It is also concluded, the greater hardness in the ZTA of the material welded with GMAW.

scholarly journals Numerical and Experimental Validation of Gas Metal Arc Welding on AISI 441 Ferritic Stainless Steel Through Mechanical and Microstructural Analysis

2022 ◽  
Author(s):  
SERAFINO CARUSO ◽  
DOMENICO UMBRELLO
Keyword(s):  
Grain Size ◽  
Residual Stresses ◽  
Arc Welding ◽  
Gas Metal Arc Welding ◽  
Microstructural Analysis ◽  
Welding Process ◽  
Production Costs ◽  
Metal Arc Welding ◽  
Residual Stresses And Strains ◽  
Welding Processes

Abstract Residual stresses and strains, distortion, heat affected zone (HAZ), grain size changes and hardness variation during gas metal arc welding (GMAW), are fundamental aspects to study and control during welding processes. For this reason, numerical simulations of the welding processes represent the more frequently used tool to better analyse the several aspects characterizing this joining process with the aim to reduce lead time and production costs. In the present study an uncoupled 3D thermo-mechanical analysis was carried out by two commercial finite element method (FEM) software to model an experimental single bead GMAW of AISI 441 at different process set-up. The experimental HAZ and measured temperatures were used to calibrate the heat source of both the used numerical codes, then a validation procedure was done to test the robustness of the two developed analytical procedures. One software was used to predict the residual stresses and strains and the distortions of the welded components, while in the second software a user routine was implemented, including a physical based model and the Hall-Petch (H-P) equation, to predict grain size change and hardness evolution respectively. The results demonstrate that the predicted mechanical and microstructural aspects agree with those experimentally found showing the reliability of the two codes in predicting the thermal phenomena characterizing the HAZ during the analysed welding process.

Modeling of Weld Dilution in Gas Metal Arc Welding Process Using Taguchi's Design of Experiments

2011 ◽  
Vol 110-116 ◽  
pp. 2963-2968 ◽  
Author(s):  
Masood Aghakhani ◽  
Ehsan Mehrdad ◽  
Ehsan Hayati ◽  
Maziar Mahdipour Jalilian ◽  
Arash Karbasian
Keyword(s):  
Mathematical Model ◽  
Arc Welding ◽  
Gas Flow ◽  
Gas Metal Arc Welding ◽  
Welding Process ◽  
Welding Parameters ◽  
Gas Flow Rate ◽  
Metal Arc Welding ◽  
Wire Feed ◽  
Plate Distance

Gas metal arc welding is a fusion welding process which has got wide applications in industry. In order to obtain a good quality weld, it is therefore, necessary to control the input welding parameters. In other words proper selection of input welding parameters in this process contribute to weld productivity. One of the important welding output parameters in this process is weld dilution affecting the quality and productivity of weldment. In this research paper using Taguchi method of design of experiments a mathematical model was developed using parameters such as, wire feed rate (W), welding voltage (V), nozzle-to-plate distance (N), welding speed (S) and gas flow rate (G) on weld dilution. After collecting data, signal-to-noise ratios (S/N) were calculated and used in order to obtain the optimum levels for every input parameter. Subsequently, using analysis of variance the significant coefficients for each input factor on the weld dilution were determined and validated. Finally a mathematical model based on regression analysis for predicting the weld dilution was obtained. Results show that wire feed rate (W),arc voltage (V) have increasing effect while Nozzle-to-plate distance (N) and welding speed (S) have decreasing effect on the dilution whereas gas Flow rate alone has almost no effect on dilution but its interaction with other parameters makes it quite significant in increasing the weld dilution

scholarly journals Reduction of Energy Input in Wire Arc Additive Manufacturing (WAAM) with Gas Metal Arc Welding (GMAW)

Materials ◽  
2020 ◽  
Vol 13 (11) ◽  
pp. 2491 ◽  
Author(s):  
Philipp Henckell ◽  
Maximilian Gierth ◽  
Yarop Ali ◽  
Jan Reimann ◽  
Jean Pierre Bergmann
Keyword(s):  
Additive Manufacturing ◽  
Arc Welding ◽  
Energy Input ◽  
Gas Metal Arc Welding ◽  
Welding Process ◽  
Energy Reduction ◽  
Main Challenge ◽  
Metal Arc Welding ◽  
Welding Processes ◽  
Wire Arc Additive Manufacturing

Wire arc additive manufacturing (WAAM) by gas metal arc welding (GMAW) is a suitable option for the production of large volume metal parts. The main challenge is the high and periodic heat input of the arc on the generated layers, which directly affects geometrical features of the layers such as height and width as well as metallurgical properties such as grain size, solidification or material hardness. Therefore, processing with reduced energy input is necessary. This can be implemented with short arc welding regimes and respectively energy reduced welding processes. A highly efficient strategy for further energy reduction is the adjustment of contact tube to work piece distance (CTWD) during the welding process. Based on the current controlled GMAW process an increase of CTWD leads to a reduction of the welding current due to increased resistivity in the extended electrode and constant voltage of the power source. This study shows the results of systematically adjusted CTWD during WAAM of low-alloyed steel. Thereby, an energy reduction of up to 40% could be implemented leading to an adaptation of geometrical and microstructural features of additively manufactured work pieces.

Analysis of the GMAW Process for Microprocessor Control of Arc Length

1987 ◽  
Vol 109 (2) ◽  
pp. 172-176 ◽  
Author(s):  
E. Kannatey-Asibu
Keyword(s):  
Arc Welding ◽  
Gas Metal Arc Welding ◽  
Welding Process ◽  
Constant Current ◽  
Order System ◽  
Arc Length ◽  
Microprocessor Control ◽  
Metal Arc Welding ◽  
Drive Motor ◽  
Welding Processes

Control of arc length is an essential component of the automation of arc welding processes. It is even more critical in gas metal arc welding where the arc length can vary substantially since it is closely tied to the melting process. Variations in arc length can greatly affect the quality of the weld produced. Even though there are currently systems available for controlling arc length, the theory necessary for microprocessor control is not fully developed. This paper develops a model of the gas metal arc welding process as a basis for arc length control, using the input to the wire feed drive motor as the control signal. The weld process is found to be first order after linearization, and that, coupled with the drive motor dynamics, produces a second-order system. The model is verified experimentally and is found to correlate very well with experimental results, the calculated time constant for the welding system in the constant current mode being 1.7 s, while the measured value is approximately 1.5 s.

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