A PROJECT REPORT

ON

“PARAMETRIC OPTIMIZATION OF METAL INNERT GAS WELDING”

SUBMITTED TO

THE INSTITUTION OF ENGINEERS (INDIA)

8 Gokhale Road, Kolkata 700 020
An ISO 9001 :2008 Certified Organization
(Established 1920, Incorporated by Royal Charter 1935)

In partial fulfilment for the requirement for

AMIE Program in
DEPARTMENT MECHANICAL ENGINEERING
By
MD ISMAIL
(ST699174-8)
Under the Guidance of
MR KHALEEL AHMED, MIE
(M-0504239)
SENIOR FACULTY MEMBER (MECH ENGG)
 THE INSTITUTION OF ENGINEERS (INDIA)
8 Gokhale Road, Kolkata 700 020
An ISO 9001 :2008 Certified Organization
(Established 1920, Incorporated by Royal Charter 1935)

CERTIFICATE

This is to certify that the project Work Entitled “PARAMETRIC

OPTIMIZATION OF METAL INNEGAS WELDING” is a Bonafide
work carried out by Mr. ISMAIL (ST699174-8) in partial fulfilment for the
award of AMIE in the Department of Mechanical engineering “The
Institution of Engineers (India )” during the year of 2023 (winter -2022)
Under my guidance.

Date :- MR. KHALEEL AHMED

(M-0534239)
 ACKNOWLEDGEMENT

Having completed my project work Successfully. I Would Like to the

Acknowledge the name of People without their help this endeavour would have
remained a dream.

I express my dee sense of gratitude to Mr. Khaleel Ahmed, MIE, Project Guide,
for this persistent encouragement, Valuable guidance and support during the
project work throughout the course

I grateful and extremely thank to Mr, Suhil Malani CEO of Kiran Udyog Pvt
ltd BIDAR His encouragement.

I Extremity thanks to Mr. Harish Joshi Plant Manager of Kiran Udyog Bidar for
his support.

I Thanks to Mr. Pradeep Kulkarni production Manager of Kiran Udyog Bidar

for his Guidance.

I Express my thanks to all my Family members and all who Everest ended direct
Or indirect help during the course of project work and almighty who helped me
out in the project work.
 DECLARATION

I Mr. Md Ismail. ST699174-8 do here by declare that this

work is an original one and has not been submitted earlier to any
other Institution for fulfilment of the requirement of a course of
study.

Date Mr.Md Ismail.

(ST699174-8)
“PARAMETRIC OPTIMIZATION OF

METAL INNERT GAS WELDING”

Approved Synopsis :

TITLE : PARAMETRIC OPTIMIZATION OF METAL INNERT GAS

WELDING

Objective of the study: - Welding represents one of the complex manufacturing

processes in terms of number of variables involved and factors contributing to the
final output or response. Welding has been used in the fabrication of structures
ranging from conventional industrial applications to high-tech engineering
applications in aeronautical, nuclear, aerospace, marine and high-pressure vessel
applications. Compared to mechanical joining methods, welding method offers
some significant advantages including flexibility of design, improved structural
integrity and weight & cost savings.

A wide range of similar and dissimilar metals can be joined by various welding
processes. Dissimilar metals welding includes relatively more difficulties than that
of welding similar metals. This is due the variation in physical and thermal
properties of the metals. In the present scenario demand of the joining of dissimilar
materials continuously increases due to their advantages, which can produce very
narrow heat affected zone (HAZ), low residual stress, and small welding defects.
Welding of stainless steel 304L with pure copper includes a large variation in
considering the parameters. In Power generation industries the copper and steel
joint have been widely been used due to their high electrical conductivity and
stiffness. The demand for producing joints of dissimilar materials is continuously
increasing due to their advantages, which can provide appropriate mechanical
properties and good cost reduction.
 Rational for the study:-TIG or GTAW welding is one of the most common
welding used in several industries for welding various metals. It is an economical
an high productivity process. This process can be used for welding both similar and
dissimilar metals and the parameters can be varied and controlled depending on
the requirements.

The use of optimization of the parameters has improved as the design and the
process parameters can be estimated without any difficulties. The optimization of
process parameters can improve quality of the product and minimize the cost of
performing lot of experiments and also reduces the wastage of the resources. The
optimal combination of the process parameters can be predicted. This project deals
with the optimum parameters that are required to obtain a proper weld and
hardness. The optimization is processed using ABAQUS
software and then experimental procedure is carried. The main parameters
considered are the voltage, current, temperature and the filler material to be used.

This Project mainly addresses about the investigation of process parameters that
result in proper welds and the simulation of temperature distribution, heat flux
distribution and direction of distortion of the base metals after welding. However,
any welding process induces the stresses in base metals and leads to distortion.
This can be observed in simulation and can be minimized by using proper
techniques.

EXPECTED CONTRIBUTION FROM THE DEVELOPMENT

The main objective of this project is to simulate the parameters that

are required to weld the copper and stainless steel and the temperature
distribution, heat flux variation over the metals at different points and the
distortion can be observed. Using these parameters, the welding is carried out
experimentally and the hardness of the weld can be measured.
 CONTENTS
SR PARTICULARS PAGE
NO
1 INTRODUCTION 1-8
2 LITERATURERE VIEW 9
3 OBJECTIVES AND METHEDOLOGY OBJECTIVE 10
4 EXPERIMENTALSETUP 11-29
5 RESULTS AND DISCUSSIONS 30-36
6 CONCLUSION 37
7 FUTURE SCOPE 38-40
LIST OF ACTIVITIES TO BE CARRIED OUT TO COMPLETE THE PROJECT
Activities Numbers of days
Project Selection 05
Project synopsis Preparation 03
Methodology of the study 05
Statement of the problem 05
Input data /Structure /questionnaire 05
Analysis and Solution 6
Final Result 5
Preparation of Project report 5
Project submission 6
Total Number of days Estimated to completion 45 Days
the project
PLACES /LABS /EQUIPMENT AND TOOLS REQUIRED
Laboratories place: -KIRAN UDYOG BIDAR
PARAMETRIC OPTIMIZATION OF METAL INNERT GAS WELDING

10
 PARAMETRIC OPTIMIZATION OF METAL INNERT GAS WELDING

CHAPTER-l

INTRODUCTION

Insulating base metals with inert gas and a consumable metal electrode allows metal
inert gas welding. This external inert gas shields the metal. This method is popular in one
among the welding methods. With a consumable solid electrode, welding quality is best
determined by current, speed, arc voltage, and electrodes. Good metal inert gas welding is
automated.

1.1 TYPES OF WELDING PROCESSES

Welding classification depends on circumstances.

(a) Heat and weight are used in combination welding.

l.l.1 Gas Welding:

This welding method uses a gas flame to heat and connect metal, dissolving metal
along the joint. A filler metal is applied to the flowing liquid metal to fill edge depressions.
Molten metal may unite two pieces of metal, which hardens and solidifies when the union
cools.

1
 PARAMETRIC OPTIMIZATION OF METAL INNERT GAS WELDING

1.1.2 Oxy-Acetylene:
Oxy-acetylene welding can weld several metals and combinations. Acetylene and
oxygen smouldered under control generate a lot of heat and raise temperature. Creating carbon
dioxide while smouldering helps prevent metal oxidation during welding. This welding may
reach 3200°C.

2C2H2 + 502 = 4C02 + 2H2O + Heat

On the basis of gas supply weight, oxy-acetylene welding is sorted welding both gases,
acetylene given to welding, low-weight welding from chamber, but calcium carbide and low-
oxygen supply pull acetylene at welding zone.

Low- and high-weight welding may be compared. High-weight welding equipment provides
clean acetylene at consistent weight, with greater control and lower costs than low-weight
welding.

1.1.3 Resistance Welding:

This welding uses heat and weight to connect. Current pouring across it and producing
resistance generates heat. The measure of heat produced is H = 2 Rt where H is the heat
created t is second, I am the current streaming and R is resistance, t is the time of which
current streams. Figure l.l.3 shows resistance welding guide line (a), Work piece to be
welded, two restricted cathodes, weight system to crush work piece, AC control supply to
maintain current, electrical switch with timings to stop streaming current after the time.

Figure 1.1: Resistance Welding

2
 PARAMETRIC OPTIMIZATION OF METAL INNERT GAS WELDING

Resistance welding is divided in to different types.

A ) Spot welding,
B ) Projection welding,
C ) Seam welding

(a) Spot welding:

It is frequently utilised in large-scale car, machine, metal furniture, and sheet metal
manufacture. Contradictory terminals combine lap joint faying surfaces in this welding. Up
to 3 mm wok thickness. An unwaterproofed joint was created. Spot weld estimate given
terminal tip size and condition. Shapes include circular, hexagonal, square, and more. Spot
welding quality matches workpiece metal quality.

B.Resistance seam welding:

In this case, pivoting wheels are welding terminals. It is like doing spot welds along the lap
joint continuously. This method creates airtight joints. The lap joint may pass between
pivoting cathodes. These cathodes push and entangle the work piece to create a continuous
lap junction. Figure l.l.3 shows how this welding is used to make gas tanks and cars (b)

3
 PARAMETRIC OPTIMIZATION OF METAL INNERT GAS WELDING

Figure l.2:- Resistance seam welding

(c) Resistance projection welding:

One or more pieces have limited contact in this welding mixture. Welding components'
shapes identify contact focuses. These pieces may have projections, embellishments, or
limited connections. This method is precise, rapid, and cheap. Anodes are designed for
certain workpieces. If large-scale production occurs, this method should be used. Figure l.l.3
shows resistance projection welding's operation(c),

Figure l.3:- Method of Resistance projection welding

4
 PARAMETRIC OPTIMIZATION OF METAL INNERT GAS WELDING

(d) Resistance percussion welding:

Blaze and percussion welding are similar. Glimmer welding produces butts. To link two
surfaces, electric current liquefies them. Compressed surfaces produce the welded
connection. Here, the joint's resistance and circular section warm it. Glimmer welding
basics. The percussion welding cycle is shorter than flame welding. Requests up to 0 m.sec.
Professional warming techniques include fast release and rapid percussion to frame the
weld. Warming is minimal. It is utilised in electrical circuit production for heat application
precision.

Tungsten or carbon. Non-softening welding anodes are non-consumable. Their

consumption is modest. Metal and flux enter non-consumable terminals. Themajority of
MIG and TIG welding employs non-consumable cathodes.

l.2 TYPES OF WELDING ELECTRODES

Also called welding rods. Typically, two welding electrodes are employed.
Consumable and non-consumable electrodes. Consumable electrodes provide arcwelding
filler metal. Consumable electrodes are coated or bare. Bare electrodes are filler metal rods
without coating. Additional flux is needed for bare electrodes.
The electrodes are seldom utilised. Gas shielded welding uses non-consumable electrodes
(MIG and UIG).

5
 PARAMETRIC OPTIMIZATION OF METAL INNERT GAS WELDING

l.2.l: NON-CONSUMABLE ELECTRODES:

Figure 1.4: Fusion Or Non-Pressure Welding

1.3 COATED CONSUMABLE ELECTRODES:

The best-known circular segment welding terminals. They need no filler metal or
flux. These anodes usually have a mild steel core and flux material coating. Terminal
covering has several purposes. It reduces oxidation, separates slag from metal pollution, and
provides air cooling for weld pool alloying. Typical fluxes for slag generation include
asbestos, mica, silica, fluorspar, satellite, titanium dioxide, iron oxide, metal carbonates, and
cellulose, dolomite, wood flour, and starch. Iron powder boosts testimony. Manganese oxide,
potassium silicate, and titanate alloy and stabilise.

6
PARAMETRIC OPTIMIZATION OF METAL INNERT GAS WELDING

Figure l.5: Pressure welding

7
 PARAMETRIC OPTIMIZATION OF METAL INNERT GAS WELDING

1.4 ELECTRODE CLASSIFICATION AND CODING:

Cathode coding is straightforward to recognise; six numbers with a prefix letter" indicate
suitable for metal circular segment welding. Six numbers are explained below.
First Digit
First, digit remains for terminal covering kind. Choose a number from l to 8.
Second Digit
From l through 6. Each number represents a terminal's welding position.
Third Digit
Zero through seven. Each number represents an anode current state.
Fourth Digit
Any numeral from l to 8 is used. Terminal with a certain number shows cathode weldment's
least flexibility.
Fifth Digit
In ductile testing, stored weldment lengthens. L to 5 refers to several rates.
Sixth Digit
Weldment base effect quality was inferred. Five classes from l to 5 arrange various quality
attributes.

8
 PARAMETRIC OPTIMIZATION OF METAL INNERT GAS WELDING

CHAPTER-2

LITERATURERE VIEW

Briefly addressed welding areas relating to the issue and assisted with this task.

[l]. Rakesh Prasad .Dr.satishkumar: parametric optimization of mild steel welding by

metal inert as welding on Taguchi technic and obtained good quality weld with good
weldability and good strength.

[2] Prakash Sharma, Amithbhudhiraj : Did Examination on heat distribution and heat
variation on weld material did on metal inert gas welding and analysed parameters of welding
Taguchi method and got good result on strength parameters.

[3] Rajendra Singh, Dr S.S Dhammi : facilitated J-C-O-E method on welding to get
strength parameters by metal inert gas welding n identified the changes in the weld strength
according to change in parameters.

[4] Dr. Manthan Thakkar : Examined different level of multi response of process
parameters on metal inert gas welding on weld metal material and got a result of good
welded.material.with.good.strength.

9
 PARAMETRIC OPTIMIZATION OF METAL INNERT GAS WELDING

CHAPTER- 3

OBJECTIVES AND METHEDOLOGY

OBJECTIVES

To reduce welding process difficulties and improve parameters:

❖ lower electric force use
❖ Reduce anode overuse
❖ Precision welding geometry
❖ Improvement in welded material
❖ Reduces work material use and
❖ Lower welding costs

3.1 METHODOLOGY:

Step l: Finding crucial process variables.

Step 2: Procedure planning.
Step 3: placing tests as planned.
Step 4: keeping response results.
Step 5: inspecting welding.
Step 6: Evaluate simplified parameter estimates.
Step 7: Reporting procedure parameters' key effects.

10
 PARAMETRIC OPTIMIZATION OF METAL INNERT GAS WELDING

CHAPTER- 4

EXPERIMENTAL SE TUP
This technique shields the base metal with inert gas. Consumable metal
electrodes and inert or active gas are used to weld base metals in this method of
arc welding. This external inert gas barrier protects weld metal. A disposable
electrode fills the metal gap to unite the two metal pieces, and the inert gas covers
the molten weld to avoid contamination.

Figure 4.1: Pressure welding

4.1 TAGUCHI METHOD:

Quality expert Taguchi has developed an orthogonal demonstrate test technique with
little fluctuation in process control variable examination. Taguchi system measures execution
by sign-to-commotion proportion. The changeability. S/N is the mean (sign) to standard
deviation ratio (clamour). Most often used S/N ratios are: Nominal is better, lower the best,
and higher the best (HB). The optimal variable mix is the highest S/N ratio.

11
 PARAMETRIC OPTIMIZATION OF METAL INNERT GAS WELDING

4.2 CONTROL PARAMETERS:

4.2.l Welding Current:

It regulates base metal anode affidavit rate. Less welding current means less base metal entry
and less cathode smouldering with high exhaust. Guardian metal thickness affects welding
current. High current causes cathodes with high exhaust turnout to burn out prematurely.
High current may overwear cathodes with higher weld on guardian metal rates. High welding
current increases anxiety risk.
Welding Speed: Welding speed is cathode-crease speed. Beyond this optimum, rate
increases reduce infiltration. In circular segment welding, increasing welding speed
decreases weld warmth per unit length.
Arc Voltage: Circular segment voltage indicates potential difference between cathode tip
and workpiece. Increased bend voltage leads to wider globules. Expanding the curve voltage
increases circular segment length, softening metal and flux and enabling more alloying
components to penetrate the weld metal. Thus, circular segment voltage affects weld metal
synthesis.
Heat Input: Welding heat is relative. It helps evaluate welding systems throughout an
operation. Weld size, cooling rate, and material properties may be affected by warmth. Heat
data is regulated in welding. Understand and employ these criteria while managing score
strength, HAZ, and welding high composite steels for high-quality welded development.

4.3 PROCESS PARAMETERS AND THEIR RANGE

PARAMETERS RANGE
1. VOLTAGE 28-36 volts
2. CURRENT 300-380 amp
3. ELECTRODE TRAVEL SPEED 300-500 mm/min

12
 PARAMETRIC OPTIMIZATION OF METAL INNERT GAS WELDING

4.3.1 WORK-MATERIAL

Figure 4.2: Parts of the metal which are been welded

For welding experiments, l50mm*l00mm*l0mm (l*B*T) is used using a 0.l percent carbon
substance for a welding preparation and alloy steel as a cathode. Mellow steel offers several
benefits, including consistent hardness and increased flexibility. This is better for repeatable
precision machining. It will also be easily accessible.

Advantages of Mild Steel: Mild steel has better accessibility than other steels.

Cost-Effective: The least expensive steel, many typical products are created with it,
including auto-versatile suspension between 0.l6 percent and 0.29 percent. The carbon core
is long and strong enough for various jobs without being too flexible. In large orders, it may
be provided at a lower cost than other steels, yielding results you can't beat.

Weldable: Mellow steel mixes easily, unlike high-carbon steel. Electric streams pass
through metal without altering its ‘make-up' due to its characteristics. It's unique that stainless
steel can be welded professionally. This reduces labour hours and electricity costs, with an
additional finish to complete its basic production.

13
 PARAMETRIC OPTIMIZATION OF METAL INNERT GAS WELDING

Ductile: Stretch without cracking is ductility. Such solid materials may expand above l5%
and lose their form. Mellow steel is easier to mould, weld, and twist than other steels.

Can be Carburized: Carburizing heats and cools steel via 'extinguishing', making the
surface hard but the inside sensitive and intense. Despite improving quality, this is a
remarkable way to improve wear attributes.

Recyclable: Most metals, discarded mild steel is essential to business. Mellow steel is easy
to recover from unsorted garbage due of its enticing characteristics. Most steel may be reused
inconclusively without losing quality. Reusing scrap as much as possible is cheaper than
mining and processing iron ore to make more. Table 4.1 Chemical composition Of, Mild
Steel

14
 PARAMETRIC OPTIMIZATION OF METAL INNERT GAS WELDING

4.1 Chemical Composition of Mild steel

l) CARB0N 0.l7-0.l9%

2) SILCON 0.50 Max %

3) MANGANESE 0.75-0.92 %

4)Sulphur 0.040 max %

5) PHOSPHORS 0.40 x%

Table 4.2 Mechanical Properties, Of Mild Steel Material In Cold Drawn Condition

Stress 4l0-5l2 N/mm2

Yield stress 30l-44l N/mm2

0.2% Proof stress 289-426N/mm2

Elongation ll-l5 %

Table 4.3 Welding, Parameters and Their level

Levels Current (Amp) Voltage (Volts) Electrode

SPEED (mm/min)
l 300 28 300
2 340 32 400
3 380 36 500

15
 PARAMETRIC OPTIMIZATION OF METAL INNERT GAS WELDING

4.4 DESIGN OF EXPERIMENT

Taguchi uses an unusual structure of orthogonal clusters to analyse the whole parameter space
with few studies. Leading investigations with little effort is this technique's finest feature.
The three parameters are considered For every experiments the three levels are considered
Complete level of opportunity for 3 parameters =3*(3-l)=6
Therefore, least no of experiment= aggregate DOF for parameters6+l=7So L9 is the nearest
orthogonal cluster.
Baseline trials for the following parameters and levels are 7. Thus, L9 is the nearest orthogonal
exhibit.

EXPERIMENT TRAIL WELDINGPARAMETERS&LEVELS

Current (Amp) Voltage (Volts) Electrode speed

(mm/min)
l l l l

2 l 2 2
3 l 3 3

4 2 l 2

5 2 2 3

6 2 3 l
7 3 l 3

8 3 2 l

9 3 3 2

Table 4.4 : L9orthogonal, Array Design And Output Responses

16
 PARAMETRIC OPTIMIZATION OF METAL INNERT GAS WELDING

Sl no Current Voltage Electrode Depth of, Bead

1 (amp) (Volts) Speed Penetration Width(mm)
(mm/min) (mm)

l 28 300 2.23 3.49

2 32 400 2.73 4.46
3 36 500 3.72 5.37
4 28 400 3.32 3.23
5 32 500 3.52 4.43
6 36 300 2.36 2.35
7 28 500 3.20 3.77
8 32 300 2.42 2.79
9 36 400 2.93 3.09

4.5 EXPERIMENTATION ON STRENGTHEVALUATION

CHARPY TEST
Work piece size: l50mm*l00mm. The sledge weighs 20kg and the mallet separates0.5m.
Material vitality testing

17
 PARAMETRIC OPTIMIZATION OF METAL INNERT GAS WELDING

4.5: Results Of, Response Characteristics Of Normal Mild Steel

Sl. No Initial weight, Final weight, E-Kg- mEnergy observed,

Ekg-m
Kg-m (I.R-F.R)
l. 26.7 20.6 6.l
2. 26.7 20.3 6.4
3. 26.7 20.l 6.6
4. 26.7 l9.8 6.9
5. 26.7 l9.5 7.2
6. 26.7 l9.3 7.4
7. 26.7 l9.5 7.2
8. 26.7 l9.8 6.9
9. 26.7 20 6.7

 Energy observed= initial weigh- final weight = 26.7- 20.6= 6.l kg-m

Table 4.6: Results Of, Response Characteristics Of Weld Mild Steel

Sl.no Initial weight, Ekg- Final weight, E-Kg- mEnergy observed, Kg-
m m (I.R-F.R)

l. 26.3 2l.6 4.7

2. 26.3 2l.3 5
3. 26.3 2l.l 5.2
4. 26.3 20.8 5.5
5. 26.3 20.5 5.8
6. 26.3 20.3 6
7. 26.3 20.5 5.8
8. 26.3 20.8 5.5
9. 26.3 20.4 5.9

 Energy observed= initial weight- final weight = 26.3- 2l.6= 4.7 kg-m

Page 18
 PARAMETRIC OPTIMIZATION OF METAL INNERT GAS WELDING

4.6 COMPRESSION TEST

In this test, compress the work piece. Maintaining the work piece vertically and applying the
heap load until it falls short. column layout

Table 4.7: Results Of, Response Characteristics Of Normal Mild Steel

s.no Area (cm2) Max. load Stress Stress
2
(kg) Kg/cm (N/mm2)

l l.5 l6.5xl03 ll000 ll00

2 l.5 l6.8xl03 ll200 ll20

3 l. 5 l7xl03 ll333.3 ll33.33

4 l.5 l7.4xl03 ll600 ll60.00

5 l.5 l7.6xl03 ll733.33 ll73.33

6 l.5 l7.5xl03 ll666.66 ll66.66

7 l.5 l7.8xl03 ll866.67 ll86.67

8 l.5 l8xl03 l2000 l200

9 l.5 l8.2xl03 l2l33.33 l2l3.33

• Stress= Ps/As = l6.5Xl03/l.5 = ll000 kg/cm2

Page 19
 PARAMETRIC OPTIMIZATION OF METAL INNERT GAS WELDING

4.8: Results Of Response Characteristics Of Weld MildSteel

sl.no Area Max.load Stress Stress (N/mm2)

(cm2) (kg) Kg/cm2

l l.8 l6.5xl03 9l66.67 9l6.66

2 l.8 l6.8xl03 9333.33 933.33

3 l.8 l7xl03 9444.44 9434.44

4 l.8 l7.4xl03 9666.67 966.67

5 l.8 l7.6xl03 9777.78 977.78

6 l.8 l7.5xl03 9722.22 972.22

7 l.8 l7.8xl03 9888.89 988.89

8 l.8 l8xl03 l0000 l000

9 l.8 l8.2xl03 l0lll.ll l0ll.ll

• Stress= Ps/As,

• Ps= Maximum load (kg)

• As=Area of material (cm)

= l6.5Xl03/l.8

= 9l66.67 kg/cm2
=9l6.667 N/mm2

Page 20
PARAMETRIC OPTIMIZATION OF METAL INNERT GAS WELDING

Figure 4.3: Welded material mild steel

Page 21
 PARAMETRIC OPTIMIZATION OF METAL INNERT GAS WELDING

4.7 BRINNEL HARDNESS TEST

Test material is exposed to a point load, and the point on the work piece is magnified. This
investigation Test material is exposed to a point load, and the point on the work piece is
magnified.
This investigation D= it represents the 2.5mm width of the bar enter d= indentation’s
diameter measured in mm.
t= Seconds (ten sec)

Figure 4.4: Brinell hardness testing machine

Page 22
PARAMETRIC OPTIMIZATION OF METAL INNERT GAS WELDING

Figure 4.5 : Microscope used to observed the indentation

Page 23
PARAMETRIC OPTIMIZATION OF METAL INNERT GAS WELDING

Figure 4.6: Ball penetrate

Page 24
 PARAMETRIC OPTIMIZATION OF METAL INNERT GAS WELDING

Table 4.10: Welded Mild Steel Response Characteristics

Sl.no D= load (kg) d=diameter Time (sec) BHN

diameter of
of bar indentation
penitrate (mm)
(mm)
l 2.5 l87.5 0.8 l0 363.36
2 2.5 l87.5 0.8 l0 363.36
3 2.5 l87.5 0.8 l0 363.36
4 2.5 l30 0.6 l0 453.48
5 2.5 l30 0.6 l0 453.48
6 2.5 l30 0.6 l0 453.48
7 2.5 l00 0.5 l0 499.30
8 2.5 l00 0.5 l0 499.30
9 2.5 l00 0.5 l0 499.30

BHN
2
In this analysis where, P= load connected, D= measurement of bar infiltrate (2.5mm),
d= diameter of indentation (mm), t= time in seconds (l0sec)

 BHN =

=228.42

Page 25
 PARAMETRIC OPTIMIZATION OF METAL INNERT GAS WELDING

4.8 TENSILE TEST

This analysis will determine yield modulus, yield point, yield stress, extremeanxiety, and
elongation.

Table 4.1l: Normal Mild Steel Response Characteristics

Sl no load ink Scale Change in StressN/ Strain E=Stress/Strain

Reading length mm E= l/2

l 0 67.2 - - - -
2 500 67.5 0.3 6.36 0.0l5 424
3 l000 67.3 0.2 l2.73 0.0l l273
4 l500 66.9 0.4 l9.l 0.02 955
5 2000 66.8 0.l 25.46 0.005 5092
6 2500 66 0.5 3l.83 0.025 l273.2
7 3000 65.5 0.7 38.20 0.035 l09l.42
8 3500 64.8 0.8 44.56 0.04 lll4
9 4000 63 l.8 50.93 0.09 565.88
l0 4500 62.3 0.7 57.3 0.035 l637.l4
1 Ultimate Stress = Ultimate load/ Area
2 Yield Stress = load at yield point/Area
3 % of Elongation = l2-ll/llxl00
4 Young's Modulus = W*ll /A*D Type equation here.
Where, W= load applied within the elastic limit
ll= Gauge length of specimen before failure
l2= Gauge length of specimen after failure D= Diameter
of the specimen and, A= Area of specimen.
2

1. Area=

78.54mm

Page 26
 PARAMETRIC OPTIMIZATION OF METAL INNERT GAS WELDING

Stress= P/A= 500/78.54= 6.36 N/mm2

Strain= Change in length/2= 0.3/2= 0.0l5
Young's Modulus= Stress/Strain= 6.36/0.0l5=424 N/mm 2

2. Stress= P/A= l000/78.54= l2.73 N/mm2

Strain=Change in length/2= 0.2/2= 0.0l
Young's Modulus= Stress/Strain= l2.73/0.0l= l273 N/mm 2

3. Stress= P/A= l500/78.54= l9.l N/mm2

Strain=Change in length/2= 0.4/2= 0.02
Young's Modulus= Stress/Strain= l9.l/0.02=955x N/mm2
4. Stress= P/A= 2000/78.54= 25.46 N/mm2
Strain=Change in length/2= 0.l/2= 0.005
Young's Modulus= Stress/Strain= 25.46/0.005= 5092 N/mm 2

5. % of Elongation= l2-ll/ll xl00

=

= l5%
In this percentage of Elongation will be of l5% due to same lengths of the material

Table 4.12 : Results Of Response Characteristics Of Weld Mild Steel

Sl no load Scale Change in Stress () Strain E=Stress/Strain

in (kg) Reading length(l) E= l/2

l 0 67.2 - - - -
2 450 67.5 0.3 5.72 0.0l5 38l.33
3 450 67.5 0.3 5.72 0.0l5 38l.33
4 450 67.5 0.3 5.72 0.0l5 38l.33
5 950 66.8 0.4 l2.09 0.02 604.5
6 950 66.8 0.4 l2.09 0.02 604.5
7 950 66.8 0.4 l2.09 0.02 604.5

Page 27
 PARAMETRIC OPTIMIZATION OF METAL INNERT GAS WELDING

8 l450 66.5 0.7 l8.46 0.035 527.42

9 l450 66.5 0.7 l8.46 0.035 527.42
l0 l450 66.5 0.7 l8.46 0.035 527.42

π∗I02
78.54mm
• Stress= P/A= 450/78.54= 5.72 N/mm2
• Young's Modulus= Stress/Strain= 5.72/0.0l5=38l.33 N/mm2
• Strain= Change in length/2= 0.3/2= 0.0l5
• Stress= P/A= l450/78.54= l8.46 N/mm 2 Strain= Change in length/2=
0.7/2= 0.035

= 2−
Young's Modulus= Stress/Strain= l8.46/0.0035=527.42 N/mm 2% of Elongation *l00 =
(24-2l/2l)*l00 =l4.28 %This computation yields 4.28 percent elongation owing to material
lengths being the same.

Page 28
 PARAMETRIC OPTIMIZATION OF METAL INNERT GAS WELDING

4.9 TORSION TEST

Calculate maximal shear stress and stiffness modulus in this test. Find the material’s mean
diameter and length.

Table 4.13: Results Of Response Characteristics Of Weld Mild Steel

Sl.no Torque Angle of Angle of Fs= = C=fs/ C in

in (kg cm) twist ( ) twist in l6T/ d3 R /L N/mm2
(T) radians
l l00 l2 0.2094 88.79 0.0ll0 807l.8 807.l
2 200 l7 0.2967 l77.58 0.0l56 ll383.3 ll38.3
3 300 20 0.349l 266.36 0.0l83 l4555.l l455.5
4 400 36 0.6284 355.l5 0.0330 l0762.l l076.2l
5 500 72 l.2568 443.94 0.066l 67l6.l8 67l.6
6 600 96 l.6757 532.72 0.0882 6039.9 603.99
7 700 l27 2.2l68 62l.5l 0.ll67 5325.7 532.5
8 800 l44 2.5l36 7l0.30 0.l323 5368.8 536.88
9 900 l83 3.l943 799.09 0.l68l 4753.6 435.36

C= Fs /
∗𝑓3 T

Fs=l6T/ d3, similarly

= / Where, L is lengths=
Shear Stress
G= Modulus of unbending nature
R= Radius of example
J= Polar snippet of dormancy

Fs= l6xl00/(nxl.793) = 88.79

=R /l =0.895x0.2095/l7 =
0.0ll0
C= Fs/ =88.79/0.0ll0 =807l.8l N/cm2 C= 807.l8 N/mm2

Page 29
 PARAMETRIC OPTIMIZATION OF METAL INNERT GAS WELDING

CHAPTER-5

RESULTS AND DISCUSSIONS

5.l RESULTS FOR PARAMETRIC OPTIMIZATION

Improvement of welding elements in nine Taguchi stages. After conducting the work
material testing, response attributes are documented and examined. Investigation of trial L9
array data. Optimization parameters were determined through Taguchi examination.

5.2 SIGNAL-TO-NOISE RATIO (S/N RATIO):

To determine optimal parameter, Taguchi is utilised. Sign-to-commotion ratio

measures execution. Dr. Taguchi's S/N % determines noise-adjusted control levels. S/N
weighs mean and variance. The S/N ratio, is the sign-to-standard deviation clamour ratio.
The typical S/N ratios are normal is-besting, lower the better (LB), and higher-the-better
(HB). This study chooses trademark attributes by globule diameter and penetration depth.
Good outcomes come from little dots and deeper penetration. Thus, LB is suggested for dot
width. HB foundation is used for infiltration depth.

Page 30
 PARAMETRIC OPTIMIZATION OF METAL INNERT GAS WELDING

Table
5.1: L9 Orthogonal, Array Design And OutputResponses

Sl no Current Voltage Electrode Depth of, Bead,

(amp) (Volts) Speed(mm/min) Penetration(mm) Width(mm)

300 28 300 2.23 3.49

2 300 32 400 2.73 4.46
3 300 36 500 3.72 5.37
4 340 28 400 3.32 3.23
5 340 32 500 3.52 4.43
6 340 36 300 2.36 2.35
7 380 28 500 3.20 3.77
8 380 32 300 2.42 2.79
9 380 36 400 2.93 3.09

5.3 S/N RATIO FOR DEPTH OF PENETRATION:

Weld joints are desirable because of their deeper entry. The S/N percentage count is better if
infiltration depth is greater. Table 3 shows that 380 amps, 32 V, and 400 mm/min are excellent
for deeper depths.

Page 31
 PARAMETRIC OPTIMIZATION OF METAL INNERT GAS WELDING

Table

5.2: Responses, For S/N Ratios Larger Is Better

levels Current Voltage Speed
l 70.704 l0.796 l3.079
2 ll0.350 l3.69l l3.507
3 l70.262 ll.829 9.729
Delta 9.559 2.895 3.778
Rank l 3 2

5.4 S/N RATIO, FOR BEAD WIDTH:

Wider dots are detrimental for weld dab joints. Since weld joints don't improve. Thus, for
dab width, lower is preferable for sign-to-noise ratio. Table 4 shows the S/N percentage
response table.

Table 5.3 Responses For S/N Ratios Smaller Is Better

levels Current (Amp) Voltage (Volts) Electrode Speed
l -l80.49 -l9.7l -2l.92
2 -2l0.4l -2l.l9 -2l.55
3 -230.ll -22.l0 -l9.53
Delta 4.62 2.39 2.39
Rank l 3 2
From table 4, ideal parameters setting for littler dab width is, present = 300-amp, voltage =
28 V, speed = 500 mm/min.

5.5 ANOVA FOR DEPTH OF PENETRATION:

Table 5 shows infiltration depth ANOVA. ANOVA table estimates information element
criticalness. If the p value in the final section of the ANOVA table is < 0.05, the component

Page 32
 PARAMETRIC OPTIMIZATION OF METAL INNERT GAS WELDING

Table
related to that estimate is large. Current study's p-value is 0.0ll, below 0.05. More important
a variable is, the higher its F value in an ANOVA table. Table 5reveals current is the most
crucial process parameter.

5.4: Analysis, Of Variance for Depth Of Penetration

Source DOF Siq’s Adj.MS F P %Contribution

n

Current(I) 2 40.3ll3 20.l556 92.93 0.0ll 77.03

Voltage 2 4.7295 203962 ll.05 0.083 9.l6
(V)
Speed (S) 2 6.794l 3.3970 l5.66 0.060 l2.99
Error 2 0.4338 0.2l69

Total 8 52.33l6

5.6 ANOVA FOR BEAD WIDTH:

ANOVA table demonstrates current P esteem is lowest when globule width is response.
Current P esteem is 0.037, below 0.05. The current's F value is strong, suggesting that it
affects response, including factor placements.

Page 33
 PARAMETRIC OPTIMIZATION OF METAL INNERT GAS WELDING

Table
5.5: Analysis Of Variance for Bead Width

Source DOF Siq’s Adj.MS F P %Contribution

n

Current(I) 2 57.094 28.547 26.29 0.037 57.33

Voltage 2 l8.034 9.0l7 8.30 0.l07 l8. ll
(V)
Speed (S) 2 22.295 ll.l47 l0.27 0.089 22.39
Error 2 2.l7l l.086

Total 8 99.595

Table 5.6 Results For, Strength Ev Aluati on Charpy Test

Sl.no Mean Energy, Mean Energy Energy
Comparison

1 absorbed for normal absorbed for Normal-Welded

2
material (kg-m) Welded material material (kg-m)
3 (kg-m)

l. 6.l3 5.48 6.l3-5.48

 We calculated the quality (vitality monitored) for typical mild steel at 6.l3kg-m and
for welded mild steel at 5.48 kg-m.

 Welded material is 0.65 kg-m more grounded than conventional mellow because the
difference between the two is 6.l3-5.48= 0.65 kg-m.

Page 34
 PARAMETRIC OPTIMIZATION OF METAL INNERT GAS WELDING

Table
5.7 Compressive Test

Sl.no Mean Stress, for normal Mean Stress for Stress Main Stress
material (mild steel) Welded material Comparison (N/mm2)
(N/mm2) (mild steel) Normal-Welded
(N/mm2) mild steel
(N/mm2)

l. ll59.40 l003.l4 ll59.40-l003.l4 l56.26

 We calculated the quality (anxiety) for ordinary mild steel at ll59.40N/mm2and for
welded mild steel at l003.l4 N/mm2.

 We may assume that welded material is l56.26 N/mm2 more grounded than
conventional soft st

Table 5.8 Brinell Hardness Test

Sl.no Mean BHN for Mean BHN for BHN Comparison Main BHN
normal material Welded material Normal-Welded
(mild steel) (mild steel) mild steel

l. 245.067 438.7l 245.067-438.7l l93.64

 Welded mild steel has a quality (BHN) of 438.7l, whereas conventional mild steel
has 245.067.
 The difference between welded and unwelded material is 245.067- 438.7l=l93.64,
suggesting welded material is more grounded than mild BHN.

Page 35
 PARAMETRIC OPTIMIZATION OF METAL INNERT GAS WELDING

Table 5.9: Tensile Test

Sl.no Mean Young's Mean Young's Young's Modulus Main

1 Modulus for Modulus for Comparison Young's
normal
2 material (mild Welded Normal-Welded Modulus
steel)
3 (N/mm2) material (mild mild steel (N/mm2)

4 steel) (N/mm2) (N/mm2)

l. l49l.7l 504.4l l49l.7l-504.4l 987.3

 We found that conventional mild steel has a Young's modulus of l49l.7lN/mm2 and
welded mild steel has 504.4l N/mm2.

 The difference between welded and unwelded material is l49l.7l- 504.4l= 987.3 N/mm2,
indicating that welded material is more grounded than soft stone.

Page 36
 PARAMETRIC OPTIMIZATION OF METAL INNERT GAS WELDING

CHAPTER- 6

CONCLUSION

 When welding current, voltage, and speed are high, results are excellent. Increased
welding current deepens quality, as molten metal beads exchange from the terminal.
 Good metal mixing occurs on hot plates.
 Main component: current. Globule width increases with voltage and current and
decreases with welding speed.
 At depth, current = 380-amp, voltage = 32 V, speed = 400 mm/min.
 Current = 300-amp, voltage = 28 V, speed = 500 mm/min with small dab width.
 Mild steel welded in Charpy Energy-absorbing 0.65 kg-m greater than mild steel
Welded metal is 56.26 N/mm2 stronger than mild steel in compression tests.
 Plain mild steel is l93.64 weaker than welded.
 Tensile testing shows welded mild steel is 987.3 N/mm2 stronger.

Page 37
 PARAMETRIC OPTIMIZATION OF METAL INNERT GAS WELDING

CHAPTER-7

FUTURE SCOPE
 Curve welding explorations have great potential. This study examines four parameters
for four attributes. Different parameters might be studied for similar or different
characteristics. Investigate how process parameters impact welding types.

 We anticipate correct welding geometry, cheap production cost, and less cathode usage
by using parameter improvement legitimately. Time is the main result of our efforts.
One way or another, sub blended bent welding materials will be very beneficial later on,
such in industry, since the quality of the welded material will be better than usual material
(gentle steel) because welding ordinary material quality will increase due to warming

Page 38
 PARAMETRIC OPTIMIZATION OF METAL INNERT GAS WELDING

REFERENCES
[1]. Pranesh et al "Study of The Effect of Process Parameters on Depth of Penetration and
Bead Width in Saw (Metal inert gas Arc Welding) Process", International Journal of
Advanced Engineering Research and Studies, E-ISSN2249-8974, PP08-l0, (July-Sept.,
20l3).
[2]. Indra Priyadarshini et al. "Experimental and Numerical Analysis Of Temperature
Distribution In Metal inert gas Arc Welding Process", International Journal of
Advanced Research in Computer Engineering &Technology Volume l, Issue 6, ISSN:
2278 - l323) (August 20l2).
[3]. ai dev Chandel et al."Optimization of Metal inert gas Arc Welding Heat Affected Zone
Toughness in X-l20M line Pipe Steel", Global Journal of Researches in Engineering
Mechanical and Mechanics Engineering, Volume l2, Issue l.0, ISSN: 2249-4596,
(July20l2).
[4]. Shahnwazalam et al. "Prediction of the Effect of Metal inert gas Arc Welding Process
Parameters on Weld Bead Width for MS l0l8 Steel", International Journal of
Engineering and Innovative Technology (IJEIT) Volume l, Issue 5, may 20l2, 22773754.

[5]. A Bhattacharya P Kumar et al. (20l2), "Experimental Investigation for Multi Response
Optimization of Bead Geometry in Metal inert gas Arc Welding using Grey Analysis", J.
Inst. Eng. India Ser. C , 93(2):l23-l32.
[6]. K Srinivasulu. Reddy, "Optimization & Prediction of Welding Parameters and Bead
Geometry in Metal inert gas Arc Welding", International Journal of Applied Engineering
Research and development (IJAERD) ISSN 2250-l584 Vol. 3, Issue 3, Aug 20l3.
[7]. Saurav Datta, Pradip Kumar Pal et al (2008). "Application of Tegu chi philosophy for
parametric optimization of bead geometry and HAZ width in metal inert gas arc welding
using a mixture of fresh flux and fused flux", International Journal of advanced
Manufacturing Technology,
[8]. N. Murugan, V. Gunaraj, (2005). "Prediction and control of weld bead geometry and
shape relationships in metal inert gas arc welding of pipes", Journal of Materials Processing
Technology, vol.l68, pp478-487.

Page 39
 PARAMETRIC OPTIMIZATION OF METAL INNERT GAS WELDING

[9]. Abhay Sharma, Ajay Kumar Chaudhary et al. "Estimation of heat source model
parameters for twin-wire metal inert gas arc welding", International Journal of Advanced
Manufacturing Technology 2009 DOI l0.l007/s00l70-009-2046-3, 45:l096ll03.
[10]. IWATA SHINJI, NISHI YASUHIKO, OZAMOTO DAISUKE. "Practical System to
Monitor and Control the Penetration Depth of Welding by Metal inert gas Arc Welding
(MIG) with Multiple Electrodes", JFE TECHNICAl REPORT, no 2l, p. 27-30, (August
2008).

[11]. SERDAR KARAOG" lU, Abdullah SEC,GIN. "Sensitivity analysis of metal inert gas
arc welding process parameters", journal of materials processing technology 2 0 2
(2008) 500-507, (2008)
[12]. JERZY NOWACKI, PAWEl RYBICKI. "The influence of welding heat input on
metal inert gas arc welded duplex steel joints imperfections" Journal of Materials
Processing Technology l64-l65 (2005) l082-l088, (2005).

Page 40