DEVELOPMENT OF MATHEMATICAL MODEL ON GAS TUNGSTEN ARC WELDING PROCESS

K.ASHOK KUMAR, 2G. SATISH, 3V.LAKSHMI NARAYANA

1, 2, 3

Department ! Me"#an$"a% En&$neer$n&, S#r$ V$'#n( En&$neer$n& C %%e&e ! r W men, )NTU*, +#$ma,aram-.3/202, An1#ra Pra1e'#, In1$a2
ashokkumark@sve !.e"u.#$, sa%#sh&@sve !.e"u.#$, 'akshm#$ara(a$av@sve !.e"u.#$ A)STRA*T + GAS TUNGSTEN ARC WELDING (GTAW) is the quality weld pro ess! It is pre"erred weldi#$ pro ess "or stai#less steel% low alloy steel% #i &el% o'alt% tita#iu(% alu(i#u(% opper% a#d (a$#esiu(! The prese#t wor& ai(s to e)aluate the e""e t o" Gas Tu#$ste# Ar Weldi#$ pro ess para(eters o# the quality o" the weld 'ead! The pro ess para(eters Weldi#$ Curre#t% Wire Dia(eter% Wire *eed Speed% Ratio o" wire "eed rate to tra)el speed a#d +late thi &#ess are ta&e# as a i#put )aria'les "or this prese#t wor&! The quality o" the weld 'ead a# 'e assessed 'y the 'ead hara teristi s su h as +e#etratio#% Rei#"or e(e#t , Width! E-peri(e#ts were o#du ted to study the e""e ts o" the weldi#$ pro ess para(eters! Statisti ally desi$#ed e-peri(e#ts with . pro ess para(eters (ea h at / le)els) are o#du ted to study the e""e t o" these para(eters o# 'ead $eo(etry! It is "ou#d "ro( the a#alysis o" )aria# e (AN01A) that the wire "eed rate% tra)el speed a#d wire dia(eter are the (ai# para(eters that i#"lue# e 'ead $eo(etry i# GTAW! 2athe(ati al (odels are de)eloped "or depth o" pe#etratio#% rei#"or e(e#t hei$ht a#d 'ead width "or GTAW usi#$ the (ultiple re$ressio# a#alysis! K,Y -OR.S 3 GTAW% Data*it )ersio# 4!5!.4% I% D% W*R% TS% +T! 12 Intr 1("t$ n Gas tungsten arc welding (GTAW), also known as tungsten inert gas (TIG) welding, is an arc welding process that uses a non-consumable tungsten electrode to produce the weld. The weld area is protected from atmospheric contamination b a shielding gas (usuall an inert gas such as argon), and a filler metal is normall used, though some welds, known as autogenous welds, do not re!uire it. A constant-current welding power suppl produces energ which is conducted across the arc through a column of highl ioni"ed gas and metal #apors known as a plasma. GTAW process is a candidate welding process, as it produces high !ualit and consistent welds and pro#ides e$cellent control of heat input. The GTAW process uses a non-consumable electrode protected b an inert gas. As this process uses a non-consumable electrode, e$tra material, if re!uired, is added through a filler wire either manuall or using a wire feeder. GTAW is most commonl used to weld thin sections of stainless steel and non-ferrous metals such as aluminum, magnesium, and copper allo s. The process grants the operator greater control o#er the weld than competing procedures such as shielded metal arc welding and gas metal arc welding, allowing for stronger, higher !ualit welds. %owe#er, it is comparati#el more comple$ and difficult to master, and furthermore, it is significantl slower than most other welding techni!ues. A related process, plasma arc welding, uses a slightl different welding torch to create a more focused welding arc and as a result is often automated. . TIG welding has become a popular choice of welding processes when high !ualit , precision welding is re!uired. GTAW is fre!uentl referred to as TIG welding. TIG welding is a commonl used high !ualit welding process. TIG welding has become a popular choice of welding processes when high !ualit , precision welding is re!uired. In TIG welding an arc is formed between a non-consumable tungsten electrode and the metal being welded. Gas is fed through the torch to shield the electrode and molten weld pool. If filler wire is used, it is added to the weld pool separatel .

&igure ' GTAW ( stem setup The weld-bead formed b the GTAW process pla s an important role in determining the mechanical properties of the weld and its !ualit . The weld-bead geometr also directl affects the comple$it of weld

schedules. The weld-bead shape parameters such as the bead width, reinforcement height and depth of penetration, shown in &igure ), are determined b the GTAW process parameters such as current, #oltage, welding speed and wire feed rate.

conducted, the anal sis is much easier and more likel to ield positi#e information about factors and le#els. In the anal sis phase is the positi#e or negati#e information concerning the selected factors and le#els is generated based on the pre#ious two phases. This phase is most statistical in nature of the three phases of the +,-. 222 Ta&("#$ met# 1 Although fractional factorial design allows a fraction of the total number of runs re!uired in the factorial design, there are no general guidelines for its application or the anal sis of the results obtained b performing the e$periments. Taguchi1s approach complements these two important areas. &irst, he clearl defines a set of general designs for factorial e$periments that co#er man applications. The special set of designs consists of orthogonal arra s (,A). The use of these arra s helps to determine the least number of e$periments needed for a gi#en set of factors. A comparison of number of e$periments in factorial design and Taguchi design is presented in Table '. (econd, he de#ised a standard method for anal sis of the results. The combination of standard e$perimental design techni!ues and anal sis methods in the Taguchi approach produces consistenc and reproducibilit rarel found in an other statistical method. Table ' 2omparison of &actorial design and Taguchi design &actorial design Taguchi &actors *e#el Total no. of +esign e$periments ) ) 3())) 3 . ) 4().) 3 3 ) '5()3) 4 6 ) ')4()6) 4 '7 ) .)654()'7) '5 3 . 4'(.3) 8 7 . )3.(.7) '4 Taguchi has established orthogonal arra s (,A) to describe a large number of e$perimental situations. The s mbolic designation for these arra s carries the ke information on the si"e of the e$periment. &or e$ample, designated arra *'4 re!uires '4 trail runs9 *8 re!uires 8 e$periments and so on. The #ertical columns of the arra s ac!uire a special combinatorial propert i.e., in an pair of columns in an ,A, all combinations of the treatment (of the two factors assigned to this pair) occur and the do so an e!ual number of times. This propert is called the balancing propert of ,As. This balancing propert permits the use of simple arithmetic to find the effect of the e$perimental factors on the response under stud . Taguchi has tabulated '4 basic orthogonal arra s that we call standard orthogonal arra s. The standard orthogonal

&igure ) Weld bead geometr 22 Stat$'t$"a% 1e'$&n ! e3per$ment' an1 TAGUCHI met# 1 A designed e$periment is the simultaneous e#aluation of two or more factors (parameters) for their abilit to affect the resultant a#erage or #ariabilit of particular product or process characteristics. To accomplish this in an effecti#e and statisticall proper fashion, the le#els of the factors are #aried in a strategic manner, the results of the particular test combinations are obser#ed, and the complete set of results is anal "ed to determine the important factors and preferred le#els, and to find whether increase or decrease of those le#els will potentiall lead to further impro#ement. The initial e$periments, often referred to as screening e$periments, are used to find the few important, significant factors out of man possible factors in#ol#ed with a product or process design. This e$periment is t picall a small e$periment with man factors at two le#els. *ater rounds of e$periments t picall in#ol#e few factors at more than two le#els to determine conditions of further impro#ement. 221 T#e p#a'e' $n 1e'$&n ! e3per$ment' The design of e$periments (+,-) process is di#ided into three main phases as (') the planning phase ()) the conducting phase (.) the anal ses phase. The planning phase is b far the most important phase for the e$periment to pro#ide the e$pected information. An e$perimenter will learn the information from an e$periment, sometimes in a positi#e sense and sometimes in a negati#e sense. /ositi#e information is an indication of which factors and which le#els lead to impro#ed product or process performance. 0egati#e information is an indication of which factors don1t lead to impro#ement, but no indication of which factors do. If the e$periment includes the real, et unknown, influential factors, the e$periment will ield negati#e information. In the planning phase factors and le#els are selected and, therefore, it is the most important stage of e$perimentation. Also, the correct selection of factors and le#els is nonstatistical in nature and is more dependent upon product and process e$pertise. The second most important phase is the conducting phase, where test results are actuall collected. If e$periments are well planned and

arra s along with the number of columns at different le#els for these arra s are listed in Table ..). Table ) (tandard ,rthogonal Arra s ;a$imum no of 0umbe ;a$imu columns At these ,rthogona r of m 0o of le#els l Arra :ows factors ) . 3 7 . *3 3 . 6 *4 4 6 *8 8 3 3 ' *') ') '' ' ' *'5 '5 '7 7 *1'5 '5 7 7 *'4 '4 4 6 ' *)7 )7 5 5 ' . *)6 )6 '. . *.) .) .' ' *1.) .) '< ' 8 ' *.5 .5 ). ' ) *1.5 .5 '5 ' ' . . ' *7< 7< ') ) '' ' *73 73 )5 7 5 *53 53 5. . ) *153 53 )' ' *4' 4' 3< 3 < A0,=A terms and notations The anal sis of #ariance computes !uantities known as degrees of freedom, sum of s!uares, mean s!uares, etc. and organi"es them in a standard tabular format. These !uantities and their interrelationships are defined as gi#en below using the following notation. = > mean s!uares (#ariance) / > percent contribution ( > sum of s!uares T > total (or results) ( > pure sum of s!uares 0 > number of e$periments f > degrees of freedom 2.& > correction factor e > error (e$perimental) n > total degrees of freedom Var$an"e The #ariance of each factor is determined b the sum of the s!uare of each trial sum result in#ol#ing the factor, di#ided b the degrees of freedom of the factor. Thus =A > (A?fA (for factor A) =@ > (@?f@ (for factor @) =2 > (2?f2 (for factor 2) =e > e?fe (for error terms)

Var$an"e rat$ The #ariance ratio is the #ariance of the factor di#ided b the error #ariance &A > =A?=e &@ > =@?=e &2 > =2?=e &e > =e?=e P(re '(m ! '4(are' The pure sum of s!uares is the sum minus the degrees of freedom times the error #ariance (AA > (A - fA B =e (A@ > (@ - f@ B =e (A2 > (2 - f2 B =e (Ae > (e - (fA Cf@Cf2) =e Per"ent C ntr$5(t$ n The percent contribution of each factor is the ratio of the factor sum to the total, e$pressed in percent /A > (A B '<<?(T/@ > (@ B '<<?(T /2 > (2 B '<<?(T /e > (e B '<<?(T 223 Se%e"t$ n ! rt# & na% arra6 ! r t#e pre'ent 7 r8 In the e$periments with gas tungsten arc welding, the number of factors chosen for stud is 7, each at . le#els. -ach factor has degrees of freedom (+,&) of ) (+,& > number of le#els-'). Therefore the e$periment under consideration has '< +,& and ' +,& for o#erall mean. 0o interaction is considered between the factors. %ence the total +,& is ''. It is re!uired to conduct at least '' e$periments to estimate the desired effect of factors. The corresponding ,A must ha#e at least '' rows and fi#e .-le#el columns. It can be seen from Table ..) that the *'4 standard arra meets re!uirements. The *'4 standard orthogonal arra is gi#en in Table ..'. It has eight columns and eighteen rows. The degree of freedom of *'4 arra is '4. In present work fi#e .-le#el factors are chosen. The structure of orthogonal arra re!uires that all the '4 e$periments indicated b the *'4 arra must be run. If one runs fewer than '4 e$periments, it would not be possible to complete the anal sis necessar to e#aluate the desired effects. Table . *'4 ()' B .6) ,rthogonal Arra and its *inear Graph. -$pt. 2olumn 0o ' ) . 3 7 5 6 4 ' ' ' ' ' ' ' ' ' ) ' ' ) ) ) ) ) ) . ' ' . . . . . . 3 ' ) ' ' ) ) . . 7 ' ) ) ) . . ' ' 5 ' ) . . ' ' ) )

6 4 8 '< '' ') '. '3 '7 '5 '6 '4

' ' ' ) ) ) ) ) ) ) ) )

. . . ' ' ' ) ) ) . . .

' ) . ' ) . ' ) . ' ) .

) . ' . ' ) ) . ' . ' )

' ) . . ' ) . ' ) ) . '

. ' ) ) . ' ' ) . . ' )

) . ' ) . ' . ' ) ' ) .

. ' ) ' ) . ) . ' ) . '

De'$&n ! E3per$ment' The process parameters selected for the present stud are Welding current, wire diameter, wire feed rate, ratio of wire feed rate to tra#el speed, and plate thickness. The ratio of wire feed rate to tra#el speed (W&:?T() is chosen as a factor instead of tra#el speed to a#oid the erratic combinations such as high tra#el speed for low feed rate etc. Three le#els are chosen for all the process parameters (also called factors). These selected factors and their le#els are gi#en in Table 3.'. Table 3 &actors and their le#els used in GTAW e$periments &actor *e#els /arameters 0otation ' ) . 2urrent(A) Wire diameter(mm) Wire feed rate(mm?min) :atio of wire feed rate to tra#el speed (mm) /ipe thickness %eat input D > I + W&: W&:?T( /T '3< '.) '7<< 5 4 '5< '.3 )<<< 4 ') '4< '.5 )7<< '< '5

Table. 7-$perimenters log sheet for GTAW Wire :atio of -$perim Wire &eed wire feed /late 2urrent -ental +iameter :ate rate to Thickness (A) 0umber (mm) (mm?m tra#el (mm) in) speed -<' '3< '.) '<<< 5 4 -<) '3< '.3 )<<< 4 ') -<. '3< '.5 .<<< '< '5 -<3 '5< '.) '<<< 4 ') -<7 '5< '.3 )<<< '< '5 -<5 '5< '.5 .<<< 5 4 -<6 '4< '.) )<<< 5 '5 -<4 '4< '.3 .<<< 4 4 -<8 '4< '.5 '<<< '< ') -'< '3< '.) .<<< '< ') -'' '3< '.3 '<<< 5 '5 -') '3< '.5 )<<< 4 4 -'. '5< '.) )<<< '< 4 -'3 '5< '.3 .<<< 5 ') -'7 '5< '.5 '<<< 4 '5 -'5 '4< '.) .<<< 4 '5 -'6 '4< '.3 '<<< '< 4 -'4 '4< '.5 )<<< 5 ') The absolute #alue of tra#el speeds at different W&:?T( ratios is gi#en below. Table. 5 Absolute #alue of tra#el speeds at different W&:?T( ratio :atio 5 4 '< W&:?T( '<<< )<<< .<<< Tra#el (peed (mm?min) '55.56 ...... 7<< ')7 )7< .67 '<< )<< .<<

Re'(%t' ! Ort# & na% Arra6 E3per$ment' &rom the microscopic e$amination we find penetration, reinforcement G width and further calculations like percentage of dilution, heat input (D), weld bead #olume (='), wire deposition #olume (=)) and wire deposition efficienc were done b using the formulas. Table 6 -$perimental results for bead geometr G F +ilution using *'4 orthogonal arra -$perimental /enetration :einforcement Width F of 0umber (/) mm (:) mm (W) mm +ilution -<' <.67 '.87 7.)7 )6.64 -<) <.8' ).)5 6.37 )4.'. -<. '.85 3.87 3.4. )4.76 -<3 <.4) '.85 ..)) )4.76 -<7 '..' ..)' ..64 )4.48 -<5 ).)7 7.'3 '<.37 .<.56 -<6 '.65 ).67 5..3 .8.'. -<4 '.8' ..') 6.)) .4.64 -<8 '.'4 ).' ..)4 .6.7<

=olume ='> Wire deposition #olume =) > -fficienc E > F of dilution >

The e$perimenters log after translating factors and their le#el #alues using *'4 arra is gi#en in Table 7

-'< -'' -') -'. -'3 -'7 -'5 -'6 -'4

<.67 <.8' <.84 <.65 ).3' ).'4 '.64 '.'3 ).'

'.87 ).)4 ).74 )..3 3.<7 ).84 ).7. '.57 ).8.

6.'. 5..3 4.)4 3.') 8.)3 ..<3 7.84 ..<) 8.5

)6.64 )4.'. )6.8. )7.4' .6.7< .8.)) 3<.<< .3.34 .8.5)

Table 4 2alculations for D, =', =) G E using *'4 orthogonal arra Weld %eat @ead Wire Wire -$perimental input (D) =olume deposition deposition 0umber kD?mm (=') (=)) mm. efficienc mm. -<' <.43 '''3 ''.' 84.33F -<) <.7< .<<< .<4< 86.3<F -<. <..5 744< 5<.3 86.33F -<3 <.74 '')< ''.' 84.88F -<7 <.3' )88. .<4< 86.'5F -<5 <.85 78<5 5<.3 86.44F -<6 '.<4 ))<4 ))5. 86.74F -<4 <.57 37.. 35)< 84.''F -<8 <.35 )<<7 )<'' 88.56F -'< <..5 ..<4 ..83 86.33F -'' <.43 '7') '73< 84.'4F -') <.7< .8.4 3<). 86.48F -'. <.3' )))3 ))5. 84.)8F -'3 <.85 37') 35)< 86.55F -'7 <.74 '865 )<'' 84.)7F -'5 <.57 ..67 ..83 88.3.F -'6 <.35 '7). '73< 84.45F -'4 '.<4 .867 3<). 84.4'F

selecti#el chosen e$periments out of the '4 e$periments for plate thickness #alues of 5 mm which is le#el ' for factor A. The other mean penetrations are also obtained in the same wa . +elta is the #ariation of the mean #alues of penetration within that factor. The effect of factors is ranked as per the magnitude of delta #alues. The highest ranked factor H21 has the ma$imum effect followed b +, A, @ and - in order. The factor effects are displa ed graphicall in &igure 3, which makes it eas to #isuali"e the relati#e effects of the #arious factors on depth of penetration. Table 8 ;ean anal sis for depth of penetration *e#el ' ) . +elta :ank A '.<3. '.5)) '.537 <.5<) . @ '.'<. '.3.) '.667 <.56) ) 2 '.'5. '..<. '.43. <.54< ' + '.586 '.3.< '.'4. <.7'. 3 '.)84 '..5) '.57< <..7) 7

Main Effects Plot for Means

Data Means
A 1.8 1.6 1.4 B C

Mean of Means

1.2 1.0 140 1.8 1.6 1.4 1.2 1.0 6 8 10 8 12 16 160 D 180 1.2 1.4 E 1.6 1000 2000 3000

&igure 3 effect of factor le#els on depth of penetration in GTAW The following obser#ations are made from the &igure 3 and Table 8 i. Wire feed rate (factor 2) has the largest effect on depth of penetration. @ increasing the feed rate from '<<< mm?min to .<<< mm?min, the depth of penetration can be increased b <.54 mm. ii. The wire diameter (factor @) has the ne$t largest effect on depth of penetration. The mean penetration is low at diameter le#el ' and high at diameter le#el .. The range of change in penetration depth is about <.56) mm. iii. 2urrent (factor A) has the ne$t effect on the depth of penetration among the factors considered in the present stud . The depth of penetration is increasing from le#el ' to le#el . is <.5<) mm. i#. The wire feed rate to tra#el speed ratio (factor +) has the ne$t largest effect on depth of penetration. Increasing the W&:?T( ratio from 5 to '< i.e., reducing the tra#el speed, can impro#e depth penetration b <.7'. mm. #. /late thickness (factor -) little effect on the depth of penetration. The mean depth of penetration is low on 4 mm plate. +epth of penetration is more on 5

&igure . Weld bead on ')mm thickness plates Ana%6'$' O! Var$an"e 9An ,a: Ana%6'$' ! Re'(%t' ! r Dept# ! Penetrat$ n &rom the e$perimental results of the '4 e$periments in Table 3, it is obser#ed that the penetration ranges from <.67 mm to ).3' mm. A summar of factor effects is tabulated in Table 6. The penetration #alue '.<3. is the a#erage of penetrations obtained in the

mm thick plate. The change in penetration depth is about <.5 mm. In the present anal sis, since the depth of penetration is the response #ariable, the higher #alue of !ualit characteristic is better. Therefore, from the &ig 3, the optimum conditions chosen are A. @. 2. +' -. Ana%6'$' ! Re'(%t' ! r Re$n! r"ement He$&#t It is obser#ed from the results tabulated in Table 6, it is obser#ed that the reinforcement ranges from '.57 mm to 3.87 mm. A summar of factor effects is tabulated in Table '< and the factor effects are displa ed graphicall in &ig 7, which makes it eas to #isuali"e the relati#e effects of the #arious factors on 2on#e$it Inde$. Table '< ;ean anal sis for reinforcement height *e#e A @ 2 + l ).55 ).)3 ' ).'7. ..'4. ).686 ) 6 ..)4 ).65 ) ).564 ).76) ).73) < ) ).7' ..33 . ..5). ).6<< ..''6 . 6 <.65 '.)< +elta '.36< <.5') <.767 6 < :ank . ) ' 3 7
Main Effects Plot for Means
Data Means
A 3.6 3.2 2.8 2.4 2.0 140 3.6 3.2 2.8 2.4 2.0 6 8 10 8 12 16 160 D 180 1.2 1.4 E 1.6 1000 2000 3000 B C

#.

reducing the tra#el speed, can decrease reinforcement b <.5') mm. /late thickness (factor -) little effect on the depth of penetration. The mean reinforcement is low on 4 mm plate. :einforcement is more on ') mm thick plate. The change in reinforcement is about <.7 mm. In the present anal sis, since the depth of penetration is the response #ariable, the higher #alue of !ualit characteristic is better. Therefore, from the &ig 7, the optimum conditions chosen are A) @. 2. +' -..

Ana%6'$' ! Re'(%t' ! r +ea1 W$1t# &rom the e$perimental results of the '4 e$periments in Table 6, it is obser#ed that the bead width ranges from ..<) mm to '<.3 mm. A summar of factor effects is tabulated in Table ''. The bead width #alue 5.763 is the a#erage of bead width obtained in the selecti#el chosen e$periments out of the '4 e$periments for current #alue of '3<A which is le#el ' for factor A. The other mean bead widths are also obtained in the same wa . +elta is the #ariation of the mean #alues of bead width within that factor. The effect of factors is ranked as per the magnitude of delta #alues. The highest ranked factor H+1 has the ma$imum effect followed b 2, -, @ and A in order. The factor effects are displa ed graphicall in &igure 5, which makes it eas to #isuali"e the relati#e effects of the #arious factors on bead width. Table '' ;ean anal sis for bead width *e#el ' ) . :ank A 5.736 7.53) <.8<7 7 @ 7..3< 5.'67 '.)3< 3 2 3.<)7 5.787 ..37< ) + 6.46< 7.457 ..7'< ' 5..8< 5.57. '.5<) .

&igure 7 effect of factor le#els on reinforcement height in GTAW The following obser#ations are made from the &ig 7 and Table '< i. Wire feed rate (factor 2) has the largest effect on reinforcement. @ increasing the feed rate from '<<< mm?min to .<<< mm?min, the reinforcement can be increased b '.36 mm. ii. The wire diameter (factor @) has the ne$t largest effect on depth of reinforcement. @ the increasing the wire diameter from '.) mm to '.5 mm, the reinforcement can be increased b '.) mm. iii. 2urrent (factor A) has the ne$t effect on the reinforcement among the factors considered in the present stud . The mean reinforcement is low at current le#el . and high at current le#el '. The range of change in penetration depth is about <.656 mm. i#. The wire feed rate to tra#el speed ratio (factor +) has the ne$t largest effect on reinforcement. Increasing the W&:?T( ratio from 5 to '< i.e.,

Mean of Means

Main Effects Plot for Means

Data Means
8 7 6 A B C

Mean of Means

5 4 140 8 7 6 5 4 6 8 10 8 12 16 160 D 180 1.2 1.4 E 1.6 1000 2000 3000

&igure 5 effect of factor le#els on bead width in GTAW The following obser#ations are made from the &igure 5 and Table '' i. The wire feed rate to tra#el speed ratio (factor +) has the largest effect on bead width. Increasing the W&:?T( ratio from 5 to '< i.e., reducing the tra#el speed, can decrease the bead width b ..7' mm.

Wire feed rate (factor 2) has the ne$t largest effect on bead width. @ increasing the feed rate from '<<< mm?min to .<<< mm?min, the bead width can be increased b ..37 mm. iii. The wire diameter (factor @) has the ne$t largest effect on bead width. The bead width is increasing from le#el ' to le#el . is <.5<) mm. i#. 2urrent (factor A) has the ne$t effect on the bead width among the factors considered in the present stud . The mean width is high at diameter le#el ' and low at diameter le#el ). The range of change in bead width is about '.)3 mm. #. /late thickness (factor -) little effect on the bead width. The mean width is high on ') mm plate. @ead width is more on '5 mm thick plate. The change in width is about '.5 mm. In the present anal sis, since the bead width is the response #ariable, the higher #alue of !ualit characteristic is better. Therefore, from the &ig 5, the optimum conditions chosen are A' @. 2. +' -). De,e% pment ! Met#amet$"a% M 1e%' The e$perimental results that are gi#en in pre#ious section are used to obtain the mathematical relationship between process parameters and bead geometr . The coefficients of mathematical models are computed b using method of multiple regressions. A commercial software +atafit has been used for the regression anal sis. This software is used to test se#eral models #i"., linear, e$ponential, power series (user defined). ,ut of all models tested the model that has high coefficient of multiple determination (:)) #alue and better t-ratio is chosen. The ade!uac of the models and the significance of coefficients are tested b appl ing anal sis of #ariance and student (T) test. The relationship between penetration (or reinforcement or width ) as response #ariable(s) and to gi#e process parameters #i"., current, wire diameter, wire feed rate, W&:?T( ratio G plate thickness as independent parameters can be e$pressed as I > '<aJ'bJ)cJ.dJ3eJ7f Where I is the penetration in mm, or con#e$it inde$ J' - current, A (factor A) J) K wire diameter, mm (factor @) J. - wire feed rate, m?min (factor 2) J3 K wire feed rate?tra#el speed ratio (factor+) J7 K plate thickness, mm (factor -) a, b, c, d, e and f - regression #ariables The multiple regression anal sis resulted the following e!uations /enetration />

ii.

:einforcement : >

-- (7.)) Width W >

--

(7..)

:egression anal sis results are presented in Table '' for depth of penetration. The ade!uac of the each model is tested b the anal sis of #ariance (A0,=A). Table ') shows the A0,=A for penetration. ;odel +efinitionL /enetration I > '<MaN$'MbN$)McN$.MdN$3MeN$7Mf 0umber of obser#ations > '4 0umber of missing obser#ations > < (ol#er t peL 0onlinear 0onlinear iteration limit > )7< +i#erging nonlinear iteration limit >'< 0umber of nonlinear iterations performed > )6 :esidual tolerance > <.<<<<<<<<<' (um of :esiduals > -3..6..).)5).'5'.--<) A#erage :esidual > -).3)85)3<.35)<<6--<. :esidual (um of (!uares (Absolute) > '.))8737)6)<')76 :esidual (um of (!uares (:elati#e) > '.))8737)6)<')76 (tandard -rror of the -stimate > <..)<<86<)78'6)'5 2oefficient of ;ultiple +etermination (:M)) > <.685.<3638. /roportion of =ariance -$plained > 68.5.<3638.F AdOusted coefficient of multiple determination (:aM)) > <.6''3.'6)4) +urbin-Watson statistic > '.78'7..848'3..7 88F 2onfidence Inter#als =ariable =alue a -3.83<'65<4)).'37 b '.345843677.)768 c '.67..4.4)534.87 d <.354.8434<747'.6 e -<.7..4747'.)<<636 f <.3577))83.6<5<.5 I> --- (7.') Table ') Anal sis of =ariance for depth of penetration model (ource +& (um of ;ean & /rob(&) (!uares (!uare :atio :egression 7 3.4<55 <.85'.. 8..4). <.<<<68 -rror ') '.))87 <.'<)35 Total '6 5.<.5)

-- (7.')

&igure 6 shows the relationship between e$perimental #alue and predicted #alue of depth of penetration in Gas Tungsten Arc Welding. It is obser#ed from the figure that the #alues predicted b penetration model (-!n. 7.') are in good agreement with e$perimental #alues. The e$perimental and predicted #alues of penetration and percentage error are gi#en in Table '.. It can be obser#ed from the table that the percentage error is less than )8F in all the cases e$cept one. %ence it is concluded that the model can predict the depth of penetration in GTAW with good accurac .

predicted the depth of penetration at different wire feed rates, W&:?T( ratio and on different plate thickness. It is obser#ed from the plots that the depth of penetration increases with increase in wire feed rate or increase in welding speed (i.e., increase in W&:?T( ratio) for a gi#en plate thickness. This is because at high wire feed rate the heat input is more and hence more depth of penetration. (imilarl at high W&:?T( ratio (low welding speed), the rate of heat input on to the weld pool is more which results in more depth of penetration for a gi#en plate thickness. &igs. 5.8 K 5.'' are useful to predict the depth of penetration at different wire feed rates and at different W&:?T( ratio. C n"%('$ n '. &rom the present work the mathematical models were de#eloped for penetration, reinforcement and width. ). 2ompression had made between the e$perimental #alues and predicted #alues (b using generated formulas) are showing reasonable agreement. Re!eren"e' ') I.(. Pim, D.(. (on, %.D. Pim and @.A. 2hin, QA stud on #ariation of shielding gas in GTA welding using finite element methodA, A;;=olume '6, issue '-), pp. )38-)7), Dul K august )<<5. I. (. Tarng and W. %. Iang Iang ;,ptimi"ation of the Weld @ead Geometr in Gas Tungsten Arc Welding b the Taguchi ;ethodA2 The InternationalR Dournal of ad#anced ;anufacturing Technolog , pp. 738 K 773, '884. +r (un Sheng, +r Puo ;in and /an +a ou, QTwin Wire Gas Tungsten Arc 2laddingA, Doining Technolog Group, /rocess Technolog +i#ision, '888. @ernard ;annion and Dack %ein"man ; +etermining parameters for GTAW<, Dul ?August '888 issue of /ractical Welding Toda . (. J. *#N, S. W. Ju, %. T. Wang and (. T. Iang ;In#estigation on TIG cladding of copper allo on steel plate <, (cience and Technolog of Welding and Doining, =olume '., pp. '<-'5, )<<4. T.Da ananda Pumar, Q-ffect of input current on dilution in claddings produced b gtaw processA, AW( Welding %andbook, 4th -dition. The Welding Institute Dournal, '67?'84), (tud of Welding /rocess /rameters. The Welding Institute Dournal, )4.?'847, +ilution. Q;odern Arc Welding Technolog A @ (.=. 0adkarni.

&igure 6 /redicted #alue =s -$perimental #alue of penetration in GTAW Table '. 2omparison between predicted #alue and e$perimental #alue of penetration in GTAWL -$p. /enetration 2alculated :esidual F -rror 0o. (/) mm (/) -<' <.67 <.5. -<.') -'7.47 -<) <.8' '.'8 <.)4 .<.). -<. '.85 '.43 -<.') -5.)) -<3 <.4) <.4< -<.<) -).66 -<7 '..' '.36 <.'5 ''.84 -<5 ).)7 ).'. -<.') -7.)) -<6 '.65 '.67 -<.<' -<.37 -<4 '.8' '.6) -<.'8 -8.6. -<8 '.'4 '.3< <.)) '4..3 -'< <.67 <.86 <.)) )8.33 -'' <.8' '.'3 <.). )7.34 -') <.84 '.)3 <.)5 )5.73 -'. <.65 <.4' <.<7 5.54 -'3 ).3' ).<3 -<..6 -'7.33 -'7 ).'4 '.7' -<.56 -.<.65 -'5 '.64 '.4) <.<3 ).<6 -'6 '.'3 <.8' -<.). -'8.67 -'4 ).' ).73 <.33 )<.43 (o the #alues of current and wire diameter are taken as '4< A and '.5 mm respecti#el for plotting

))

.)

3)

7)

5) 6) 4) 8) '<)

'') ')) '.) '3)

Q;etals %andbook, 4th -dition, =ol-'A /roperties and selection of metals of American societ for metals. Q;aterials %andbookA @ AW(. QThe /rocedure %andbook of Arc WeldingA ')th -dition, @ *incoln. Q;echanical ;etallurg A @ *innert.