AIJREAS VOLUME 6, ISSUE 1 (2021, JAN) (ISSN-2455-6300)ONLINE

Anveshana’s International Journal of Research in Engineering and Applied Sciences

TIG WELDING PROCESS PARAMETERS OPTIMIZATION FOR

STAINLESS STEEL MATERIALS USING REGRESSION ANALYSIS

MACHARLA ANIL P.PRAVEEN KUMAR REDDY

M.Tech, Assistant Professor, Department M.Tech, Assistant Professor, Department
of Mechanical Engineering, Mahaveer of Mechanical Engineering, Mahaveer
Institute of Science & Technology, Institute of Science & Technology,
Hyderabad. Hyderabad.
[email protected] [email protected]

ABSTRACT: technique may be used with or without

filler metal to weld thin or dense materials.
In today's manufacturing market, mainly quality Filler metals are not used for welding
and productivity play a significant role. Every
manufacturing firm aims at producing a larger
thinner materials, edge joints, and flanges.
number of units within a short time. The For thicker fabrics, an externally fed filler
experiments have been planned using the design of wire is generally used. The type of filler
experiments and followed by regression analysis. metal wire used is based on the chemical
The welding parameters used are Weld Current (I analysis of the base metal. The filler metal
amps), Gas flow rate (FR L/min), and Root Gap (G
mm). The effect of welding parameters, distortion
wire size depends on the base metal's
(mm), and tensile strength (N/mm2) can be thickness, Which typically determines the
calculate, and the optimum welding condition can current of welding. The process methods
be determined to mitigate distortion and tensile can be manual or automatic for GTAW.
strength. An L4 orthogonal array was taken for an Which typically determines the current of
experimental layout to analyze each parameter's
effect on the welding characteristics and predict
welding. The process methods can be
each weld parameter's optimal choice, such as manual or automatic for GTAW.
weld current, Gas flow rate, and root gap. The
impact of this parameter in Distortion (D) and
Tensile Strength (TS) is analyzed. Optimization of 2. LITERATURE REVIEW
welding parameters is valuable in terms of DS. Nagesh, G.L. Datta. et.al.., Presents
providing high precision and efficient welding for welding procedure variables that control
massive structures. Optimization of welding
parameters is essential for a manufacturing unit to the welding process and the quality of the
respond effectively to fierce competitiveness and welds produced. The joint configuration is
increasing demand for quality products in the determined by the weldment design, the
market. In the welding process, the optimization of metallurgical analysis, and the process and
weld process parameters is considered a vital tool procedure required by the
for improving the output quality and reducing the
overall production time. weldment[1].J.Tusek, M. Suban, et al.
studied the influence of the chemical
Keywords: Universal testing machine, TIG composition of flux and microstructure
welding, Annova, etc. and tensile properties of welding joint. The
metallurgical advantage of pulsed current
1. INTRODUCTION welding is frequently reported in the
Welding is the powerful metal joining literature. Parameters like weld current,
techniques used in the industrial sector. Arc length, and root gap may affect the
Even after evaluating several modern weld bead geometry, heat-affected zone,
manufacturing techniques, welding still and mechanical properties of weldment
plays a vital role on the shop floor.GTAW [2]. Mohandas T, Madhusudhana .et. al.
is flexible and can be used in both welding describes the area of Gas Tungsten Arc
positions on ferrous and nonferrous metals Welding indicates the necessity of
and, depending on the base metal. The systematic investigation of the process

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parameters on Bead Width, Bead Height, parameter is assessed at two levels (with
Heat Input, Transverse Shrinkage, Area of one trial on each specimen). Trails are
Penetration, and Tensile Strength[3]. Few
reachers like T Mohandas, G conducted, and the response characteristics
Madhusudhan Reddy, Mohammad Naveed are studied for distortion and tensile
.et.al.,.He worked on the optimization of strength.
weld bead geometry on the Tig welding
2.2.EXPERIMENTAL PLAN
process. But very few investigations were
carried at optimizing the process parameter
of SMAW[4]. User Esme, Melih
Bayramoglu, Yugut Kazancoglu, Sueda
Ozgun, .et.al. presents that the Taguchi
method is a powerful statistical tool that
yields optimized parameter values
For features of the design response. Using
Orthogonal array coupled with Meticulous
experimental design a standard or S/N
analysis of results using Taguchi
techniques gives optimum parameters with
the minimum amount of experimentation
[5]. The purpose of regression testing is to
ensure that changes such as those
mentioned above have not introduced new
faults. One of the main reasons for
regression testing is to determine whether
a change in one part of the software affects
other software parts. Standard regression
testing methods include re-running
previously completed tests and checking
whether program behavior has changed
and whether fixed faults have re-emerged.
Regression testing can be performed to test
a system efficiently by systematically
selecting the appropriate minimum set of
tests needed to cover a particular 3. EXPERIMENTAL WORK
adequately. Therefore, in most software 3.1.WORKPIECE MATERIAL
development situations, it is considered
good coding practice. When a bug is AISI type 316l stainless steel is
located and fixed, record a test that used in the current experiment, with many
exposes the bug and re-run that test advantages such as low thermal
regularly after subsequent changes to the conductivity, high corrosion resistance,
program and improved stability at elevated
temperatures, and is also used in various
2.1.DEFINITION OF PROBLEM
industries, including electronics, medical
In this investigation, an attempt was made equipment, home appliances, automotive,
to determine the optimum process and advanced tube industry. It has
parameters TIG on SS316L plates. Process excellent characteristics for shaping and
parameters considered are weld current, welding
gas flow rate, and root gap. Each process

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Tensile Yield Density

strength strength

515 Mpa 290 Mpa 7.99 g/cm3

Melting Thermal %
point conductivity Elongation

1400- 21.4 W/mo K 20

1450oc at 500oc

Table-3.1 Properties of AISI 316l Steel

3.2. EXPERIMENTAL SET-UP

When selecting a TIG welding machine,

you should know how much power and
Figure 3.1: Tig Welding Experimental
sophistication are needed for the job. It is
Set Up
also necessary to ascertain the volume of
such jobs currently on hand and the
projected business for TIG welding. The TIG welding is mostly used for different
next question is - does one need an AC or welding kinds of alloys of aluminum and
DC power source. Professionals say that stainless steel, where quality is of
aluminum and magnesium are two metals importance. TIG welding is mainly used in
that are best welded using the AC output aeronautical constructions and the
from the power source. Steels and stainless chemical and nuclear power industry.
steels are most often fused with DC
output. To weld a variety of metals, use a 3.3. EXPERIMENTAL RESULTS AND
combination AC/DC machine. If the ANALYSIS
power source is either moved around the
shop or taken from one site to another, Butt-welded joints are prepared as per the
then a portable welder is needed. There are experimental plan given in Table 3.6. For
two basic ways to accomplish portability - each of the Butt-welded joints made, the
inverters and engine-driven welders. responses are the Bead Width, Bead
Inverters are now available that weigh Height, Transverse Shrinkage, Heat Input,
around 13 kg and come with handles for Area of Penetration, and Tensile Strength,
easy shifting around. which are experimentally determined.
After getting the experimental results, the
results are analyzed to arrive at optimum
values of process parameters.
Experimental results are given in Table
3.2.

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S. Paramet Weldin Root Gas

No ers/ g Gap Flow
Levels Curren Rate
t (Mm)
(L/Min)
(Amp)

1 Level-1 80 1 8

2 Level -2 90 2 10

Table 3.2 Process parameters for

welding

Welding Output
parameter levels
Trial
Distorti Tensile
No
on strengt Fig 3.3 standard specimen for tensile
A B C
h
test
1 80 1 8 0.7 203
4.RESULTS & DISCUSSIONS:
2 80 2 10 1.5 196

3 90 1 10 0.9 224 The experiment was performed on

material grade SS 316L with experiment
4 90 2 8 0.7 213
architecture (DOE). Using a dial gauge
and the universal test unit, the output
factors are absorbed.Table 3.3 the input
Table 3.3 Experimental results for the parameters that are taken for
weld bead geometry experimentation and results. Fig 4.1 shows
the tensile strength values, and in fig: 4.2
shows the distortion values of the
experiments.

230
Tensile strength
(MPa)
220
Tensile Strength (Mpa)

210

200
Tensile
strength
190 (MPa)

180
1 2 3 4
Trail Numbers
Fig 3.2: Welded samples as per the
Fig: 4.1 shows the tensile strength vs.
experiment plan experimental trails

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The linear regression equation for tensile

Distortion (mm) strength:
1.6
1.4
Distortion (mm)

1.2
TS = 252.75 + (-0.65*80) + (0*1) +
1 (1.75*10) = 217.5 Mpa
0.8 TS = 252.75 + (-0.65*90) + (0*2) +
0.6 (1.75*8) = 208Mpa
0.4 Distortio
0.2 n (mm) Exp.No Experimental Model Error
0 Values Eqn. (%)
1 2 3 4
Values
Trails Numbers
3 224 217.5 3.33
Fig: 4.2 shows the distortion vs. 4 213 208 2.83
experimental trails
Table 4.2 Comparison of experimental
The Table 3.3 shows the values of the and model equation for tensile strength
input parameters that were obtained as
optimum experimental values. These
The linear regression equation for
values were used in the confirmation tests,
and the error percentage was calculated by distortion:
comparing them with the model
experimental values. Distortion = Bo + B1* I+ B2 * RG + B3*
FR
Exp Curre Root Gas Tensile Distortio
.No nt Gap(M Flow Strengt n
(Amps m) (L/Min) h (Mm) Bo, B1, B2, B3are constants. I, RG, and FR
) (Mpa)
are the input parameters.
3. 80 1 10 224 0.9

The linear regression equation for

4. 90 2 8 213 0.7
distortion:

Table 4.1 Optimum experimental values D = (-2.65) + (0.02*80) + (0*1) +

(0.02*10) = 1 mm
The model equation used for the D = (-2.65) + (0.02*80) + (0*1) +
confirmation tests and correlation between (0.02*10) = 0.75 mm
input factors and the measured output
parameters obtained by linear regression Exp.No Experimental Model Error
analysis is given below. Values Eqn. (%)
Values
Tensile strength = Bo + B1* I+ B2 * RG + 3 0.9 1 10
B3* FR
4 0.7 0.75 6.66

Bo, B1, B2, B3are constants. I, RG, and FR Table 4.3 Comparison of experimental
are the input parameters. and model equation for distortion

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We can see from the results that the inert  The effects on tensile strength and
gas flow rate substantially affects tensile distortion of process parameters is
strength and impact the distortion. Gas discussed in the current analysis.
flow rate affects the heat input by trying to
spread over the region of the molten metal.  The DOE method is used to do the
This increases the heat addition over that numerical simulation of
small weld area to increase the penetration experiments, and experiments are
and decrease the metal deposition rate. carried out to determine Values for
Also, since the metal is in a liquid state for tensile strength and distortion.
a more significant amount of time, it
spreads over the base metal, and tensile  To achieve the optimal values
strength increases. Welding current affects Regression analysis is used, and
both tensile strength and distortion. This the experimental values are
welding current increases the arc length compared with these values.
and hence the heat input. This increase in
heat input causes the spreading of the arc  The error percentage is found to be
cone at its base, which leads to an increase below 4 percent between
in tensile strength. The interactions experimental and regression values
between current and voltage significantly for tensile strength.
affect the material's tensile strength. As
evident from the error's effects within 10  The error percentage is found to be
percent, the confirmation tests below 11 percent between
demonstrated a closer agreement of experimental and regression values
prediction with experimental findings.It for tensile strength.
proves the selected regression analysis's
effectiveness to better predict tensile References:
strength and distortion.
1. Study of type 316L stainless steel TIG welding
with MoO 3 powder Article Jul 2011 Kuang
Conclusions: Hung TsengKo Jui Chuang

The following findings are made after 2. The effect of activating fluxes on 316L
stainless steel weld joint characteristic in TIG
performing the experiments and evaluating welding using the Taguchi method ArticleE.
the experimental outcomes. The regression Ahmadi Alireza Ebrahimi
analysis has been successfully employed 3. TIG welding with single-component fluxes
for optimizing the process parameters of Article Mar 2000J MATER PROCESS TECH
Tungsten Inert Gas Welding of steel Paulo J. Modenesi Eustaquio Roberto
Apolinario Iaci Miranda Pereira
plates. It has been shown that the
regression analysis provides a systematic 4. Performance of activated TIG process in
and efficient methodology for searching austenitic stainless steel welds
the welding process parameters with Article Mar 2011J MATER PROCESS TECH
optimal weld structures. Kuang-Hung TsengChih-Yu Hsu

 Parameters of the welding process 5. Arc-Zone.com (2009). "Tungsten Selection"

(PDF). Carlsbad, California: Arc-Zone.com.
are chosen as study factors, such as Retrieved 15 June 2015.
welding current, root gap, and gas
flow rate. Using DOE, the process 6. American Welding Society (2004). Welding
parameters are selected. handbook, welding processes Part 1. Miami
Florida: American Welding Society. ISBN 978-
0-87171-729-0.

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