InternationalJournalofAdvancedResearchinTechnology,EngineeringandScience(ABimonthlyOpenAccess

OnlineJournal)Volume2,Issue2,MarchApril,2015.ISSN:23497173(Online).

Effect of Welding Current, Arc Voltage and Gas

Flow Rate on Depth of Penetration during MIG
Welding of AA2014 Plate
R.Sakthivel1*, P.Venkadeshwaran1, R.Sridevi1, R.Ahamed Meeran1, K.Chandrasekaran1 .
____________________________________________
Abstract:
In the present work, bead-on -plate welds were carried
out on AA2014 Aluminum Alloy plate using Metal Inert
Gas Welding (MIG) process. In this present investigation
ER4043 solid wire having 1.2 mm diameter was used as
an electrode with direct current electrode positive
polarity. An argon gas was employed for shielding
purposes. The fusion zone is generally characterized by a
few geometrical features namely bead width,
reinforcement and depth of penetration. The shape of the
fusion zone depends upon a number of parameters such
as gas flow rate, voltage and welding current. Taguchi
Technique is applied to plan the experiments. The weld
bead geometry plays an important role in determining the
mechanical properties of a weld joint. Therefore, it is
important to set up proper welding parameters to produce
a good weld bead.
______________________________________________
Keywords: MIG welding, AA2014 plate, Taguchi
orthogonal array, bead geometry.

___________________________________________
1. Introduction:
Metal Inert Gas welding (MIG) process is an important
component in many industrial operations. The GMAW
parameters are the most important factors affecting the
quality, productivity and cost of welding [1].GMAW
process a continuous and consumable wire electrode is
used. A shielding gas generally argon or sometimes
mixture of argon and carbon dioxide are blown through a
welding gun to the weld zone. Electrode melts due to the
heat and molten filler metal falls on the heated joint [2].
Machinability of aluminum alloy 2014 is very good.
Typical applications of aluminum alloy 2014 are high
strength components especially for use in the aerospace
and marine industries .The aluminum alloys and copper are
difficult to weld because of the high thermal conductivity,
high thermal expansion and a tendency to give porous

welds. T6 - Solution heat treated and artificially aged [3].

During a manual welding operation, the welder has to have
control over the welding variables, which affect the weld
penetration, bead geometry and the overall weld quality. A
proper selection of welding variables will increase the
chances of producing welds of a satisfactory quality
[4].The weld and bead geometry plays an important role in
determining the mechanical properties of the weld [5].
Hence the input welding process variables which influence
the bead geometry must therefore be properly selected to
obtain an acceptable high quality joint [6]. They conducted
experiments based on five process parameters to obtain
bead geometry using GMAW process. From the study it
was inferred that welding voltage, arc current, welding
speed and welding angle have large significant effects on
bead geometry developed an approach to predict and
optimize weld bead geometry in GMAW [7].The bead
geometry and penetration affect the weldments
characteristics and are dependent on a number of welding
variables. In the present investigation an attempt was made
to study some of the weldments characteristics such as
bead height, bead width and depth of penetration, as
affected by welding parameters like arc-voltage, travel
speed, wire feed rate and gas flow rate. And also its effect
of the microstructural changes in the weld zone and
hardness variation across the bead on the MIG welded
AA2014 plate [8]. Dr. Taguchi of Nippon Telephones and
Telegraph Company, Japan has established a method based
on "orthogonal array" experiments which gives much
reduced "variance" for the experiment with "optimum
settings" of control variables. Thus the marriage of Design
of Experiments with optimization of control parameters to
find best results is attained in the Taguchi Method. Taguchi
technique is used to increases the output and reduced the
cost of the products. The Taguchi Design is based on
orthogonal array. Taguchi design recognizes the control
factors to minimize the effect of Noise factor. Orthogonal
array helps to reduced the time and cost of the experiment.

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015.ISSN:234
497173(Online).

The Signal-to-Noise (S/N) Ratio

o which are log
g function of
uired output, which
w
is the objective funnction to be
requ
optim
mized [9]. A Schematic Diagram of GM
MAW System

has been shown in F

Figure 1. A schematic
s
illusstration of
w
applicaations has beenn shown in
bead peenetration in welding
Figure 2.

Fig.1. A Schematic Diagram

D
of GM
MAW System
currentt the welding voltage was varied as V11=25V &
voltagee the current w
was I1=75A & I2=100A
I
and aat constant
V2=30V.Tensile streength is morre when currrent is at
Toughness propperty is foundd to be good att V1=25V
100A.T
and othher are nearer tto it. Hardness is more at I1=
=75A & at
V2=30V.Latfe,et al.[11] MIG weldding is a well established
m alloys, althouugh some
way off joining varioous aluminum
alloys, notably thosee in the 2XXX
X and 7XXX series,
s
are
a electric
difficullt to fusion weeld. MIG weldding employs an
arc, strruck between the filler rod and the material being
weldedd, to generatee localized heeat.Due to thee reactive
nature of aluminum, the arc is shrrouded by an inert gas,
m contact
generallly argon, prootecting the baase metal from
Fig.2.
F
A Schem
matic diagram of weld bead geometry
g
with oxygen,
o
nitrogeen or hydrogeen. Rakesh Shharma, et
al.[12] After the wellding process, the weld beadd samples
L
Revviews
2. Literature
are cutt from each weeld bead at 15 mm intervalss, with the
Literrature shows that
t
work has been exploredd on various
first saample being loocated at 15 mm
m behind thhe trailing
aspeects of modelin
ng, simulationn and process optimization
edge of
o the crater eend to eliminaate the end efffects. The
in MIG
M welding. In
I this study, detailed analyysis has been
transveerse faces of thhe specimens were
w further preepared for
mad
de to establlish relationsships betweeen welding
study of
o weld bead geometry. Sppecimens weree polished
paraameters and weld
w
bead geometry and weld
w
quality
with various grades of emery pappers, starting w
with 150,
lead
ding to an optiimal process. P K Palani, et
e al.[9] The
20, 400, 800, 1200 and SIA
A Signor B 16000. Water
180, 32
DOE
E using Taguchhi approach caan significantly
y reduce time
was used as coolant. The bead geoometry was meeasured on
requ
uired for expperimental invvestigations 6-8.
6
In this
m
T
The
bead
the etcched sample by optical microscopy.
inveestigation, in thhe first stage, Taguchi's
T
orthoogonal arrays
dimenssions of the weeldment were measured
m
from
m the base
weree used to conduct
c
the experiments
e
t find the
to
metal. Sathiya, et al.[[13]Summariziing, it can be stated
s
that
conttributions of eaach factor and to optimize th
he parameter
a
penetratioon affect the weldment
the beaad geometry and
settings.
charactteristics and arre dependent on
o a number of
o welding
W
alum
minum alloy
Oladdele, et al.[10]] Worked on Wrought
variables. In the preseent investigatioon an attempt w
was made
for investigation using MIG welding
w
.The current and
y some of the weldment charracteristics succh as bead
to study
p
currrent and voltaage on tensile
voltaage is used as parameters
height, bead width annd depth of pen
netration, as afffected by
strenngth, Since inn arc welding is directly rellated voltage
g parameters liike arc-voltagee, travel speed, wire feed
welding
and current, the tw
wo conditions are applied i.ee. at constant
rate annd gas flow rate. And also
a
its effecct of the

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015.ISSN:234
497173(Online).

micrrostructural ch
hanges in the weld zone and
a
hardness
variaation across th
he beads on thee GMA weldedd AISI 904 L
(UN
NS N08904) supper austenitic stainless
s
steel.
3.E
Exprimental Details
D
The experiments were
w
carried onn AA2014 alum
minum alloy
platees of size 1500mm 50mm 6mm. GMA
AW welding
was used in experriments as it cooncentrates thee heat in the
4
electrodees of diameter 1.2
1 mm were
weldding area. ER 4043
taken as electrodee for this experiment. Beforee performing
the actual
a
experim
ment a numberr of trial experriments have

been performed
p
to get the approopriate parameeter range
where welding
w
could be possible annd no observabble defects
like undercutting
u
aand porosity occurred. The
T
bead
geomettry was measuured on the ettched sample by
b optical
microsccopy. The beaad dimensions of the weldm
ments were
measurred from the bbase metal. The chemical composition
of AA
A2014 and thee filler materiaal is given inn table 1.
Factorss affecting the GMAW weld
ding and their levels are
given in table 2 annd the experim
mental layout using L9
orthogoonal array are given
g
in table 3.
3

Material
M

Cu

M
Mg

Mn

Fe

Si

Zn

Ti

C
Cr

A
Al

A
AA2014

4.2

0
0.6

0.2

0.5

0.7

0.2

00.15

0.1

REM
M 95.17

Filler wire
ER4043

Cu
0.30

M
Mg
0..05

Mn
0.05

Fe
0.8

Si
4.5

Zn
0.10

Ti
00.20

Br
0.00033

A
Al
RE
EM

Table 1. Chhemical compoosition of base metal and filleer wire used

varriables

U
Unit

Leveel-1

Level-22

Level-3

Cu
urrent

A
Amp

180
0

200

220

Voltage

v
volt

244

26

28

Gaas flow
rate

Litt/min

177

19

21

Table
T
2. Levell of GMAW welding
w
processs variable
Samp
ple no

Current
C
(A)

Voltage
V
(V)

Gas flow
rate (L/min))

180

24

17

180

26

19

180

28

21

200

24

19

200

26

21

200

28

17

220

24

21

220

26

17

220

28

19

4. Ressult and Discu

ussion
The macrograph
m
of the welded sample
s
is preesented in
Figure 3, It is observed that the surrface of the weelded plate
n and good. Thhe weld zone, iff free from cracks for all
is clean
the exp
perimental runns is considerred for bead geometry
measurrement. The exxperimental reesults for the weld
w
bead
geomettry are presennted in Table 4. Heat input plays an
importaant factor for determining the bead geoometry. In
generall, due to the hhigh amount of
o heat input i.e.,
i
larger
amountt of heat depoosited on the surface leads to higher
penetraation.

ograph of the welded

w
samplle
Fig.3. Macro

Table 3.
3 L 9 orthogonnal array desiggn

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OnlineJournal)Volume2,Issue2,MarchApril,2015.ISSN:23497173(Online).

Sample no

Current
(A)

Voltage
(V)

Gas flow
rate (L/min)

Depth of
penetration
(mm)

Bead width
(mm)

Bead height
(mm)

180

24

17

7.28

11.99

1.92

180

26

19

7.33

11.9

2.05

180

28

21

7.38

12.0

2.90

200

24

19

8.20

12.4

3.30

200

26

21

7.38

12.0

2.78

200

28

17

8.10

12.24

3.26

220

24

21

7.22

12.23

1.58

220

26

17

7.96

14.29

3.24

220

28

19

7.16

15.20

3.02

Table 4. Experimentally measured values

4.1 Level average response analysis using average value
The level average analysis is based on combining and
averaging the response associated with each level for each
factor. From the average data of each of the experiments
where in one level of each factor occurs, the optimum
value of factors is determined. For the analysis of weld
quality generated by MIG welding process, penetration,
bead width and bead height of the weld were considered.
From the level average response analysis using the average
values of each trial run, the optimum conditions for each of
the factors Voltage (V), Welding Current (I) and Gas Flow
Rate (G) can be determined. Average effect of current on
bead dimensions are given in Table 5, Average effect of
welding voltage on bead dimensions 6 and Average effect
of gas flow rate on bead dimensions 7.
Welding
Depth of
Bead
Bead
Current
penetration
width
height
(mm)
(mm)
(mm)
(A)
180

7.33

11.96

2.29

200

7.89

12.22

3.12

220

7.45

14

2.62

Table 5. Average effect of welding current on bead

dimensions

Welding
Voltage
(V)

Depth of
penetration
(mm)

Bead
width
(mm)

Bead
height
(mm)

24

7.57

12.20

2.27

26

7.56

12.73

2.69

28

7.55

13.14

3.06

Table 6. Average effect of voltage on bead dimensions

Welding Gas
flow
rate (L/min)
17

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Depth of
penetration
(mm)
7.78

Bead
width
(mm)

Bead
height
(mm)

12.84

2.80

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19
1

7.56

21
2

7.33

13.17
12.08

2.79
2.42

Table 7. Aveerage effect of gas flow rate on

o bead
dimensioons
4.1
1.1 Effect of cu
urrent on bead
d dimensions
The value of weldding current useed in MIG hass the greatest
effecct on the deposition rate, the weld bead sizze, shape and
the penetration.
p
th
he current will increase the depth
d
and the
widtth of the weld penetration
p
andd the size of thhe weld bead.
An excessively
e
low welding currrent for a giv
ven electrode
size produces a pooor penetration and the pileupp of the weld
metaal on the surfacce of the base metal transfer by the arc is
sluggish, the beadd is rough andd reinforcemennt high If the
t weld bead is large and
curreent is too highh, the size of the
the excessive
e
deepp penetration that
t
wastes thee filler metal
causses burn-through and underccut. Too highh or too low
weldding current also affects thee mechanical properties
p
of
the weld
w metal andd the tensile strrength. Effect of
o current on
bead
d dimensions are
a shown in figgure 4.

voltagee may cause poorosity and oveerlapping at thee edges of

the weeld bead. Effecct of voltage on
o bead dimennsions are
shown in figure 5.

b
dimensionns
Fig.5. Effect of voltage on bead
4.1.3 Effect of gas flow rate on bead diimensions
m mixtures aree used in
Argon, helium and argon-helium
n
m
metals
and
many applications ffor welding non-ferrous
alloys. These inert gaas mixtures proovide lower meelting rate,
b
contour. Argon is
smallerr penetration and narrow bead
cheaper than helium and helium-arggon mixtures aand it also
produces less spatterr. Unlike argon, helium impproves the
b
penetratioon profile (high
her melting raate, deeper
weld bead
penetraation and convvex surface pro
ofile). But, wheen helium
is usedd, welding volttage rises for the
t same arc length and
the con
nsumption of shhielding gas inncreases more than
t
when
argon is
i used. Effectt of gas flow rate
r
on bead diimensions
are shoown in figure 6.

Fig.4. Effeect of current on

o bead dimenssions
1.2 Effect of voltage
v
on bead
d dimensions
4.1
In MIG
M
the arc voltage has a decided effeect upon the
peneetration, the bead
b
reinforcem
ment and bead
d width. By
increeasing the arcc voltage the weld
w
bead beccomes flatter
and wider, the pen
netration increaases until an opptimum value
t
voltage iss reached, at which time it
i begins to
of the
decrrease. Low voltage
v
producces narrower beads with
greaater convexity (high crown
n), but an exxcessive low

o bead dimenssions
Fiig.6. Effect of gas flow rate on

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497173(Online).

4.1
1.4 Macrograp
ph of the Bead
d geometry Profiles
The smooth bead
d profile microo graphs are presented
p
in
ure 2. The fusiion line zone is
i clearly visibble in all the
Figu
micrro graphs. In Figure 7 (sam
mple 1 to 9) the
t depth of
peneetration is partiially full in all the micro grapphs.

Fiig.7. Macrograaph of the Bead

d geometry Proofiles
5. Conclusioons
The preesent focus onn MIG welding
g parameter onn AA2014
under different weldding condition
n the followinng on the
me of this reseaarch.
outcom
1.The effect of wellding current increases the depth of
h
are
penetraation is constannt, the bead wiidth and bead height
increassed.
2.The effect of arrc voltage in
ncreases the depth of
h
are
penetraation is constannt, the bead wiidth and bead height
increassed.
3.The effect of gass flow rate increases
i
the depth of
penetraation, the bead width and beaad height are deecreased.
Referencess
[1] S. V.. Sapakal, M. T. Telsang,
T
2012. Paarametic optimizaation of MIG
welding using Taguchi dessign method ,International Journal oof Advanced
Engineerring Research and Studies,Vol. I,Issuue IV,July-Sept., 22012
[2] Kulekkci, M. 2005 Metaallurgy, vol .44, Noo.3.
[3] Alum
minum welding guiide, www.harriscaal .com
[4] Ramanaiah, N. 2004 IInternational Sym
mposium of Researrch Students
on Materials Science and Engineering Deccember 20-22, Chhennai, India
ment of Metallurgiccal and Materials Engineering, Inddian Institute
Departm
of Technnology Madras.
[5], Y.S. and W.H.,Yang, 1998. Optimizattion of weld bead geometry in
GTAW by
b Taguchi method, Int J Adv Mannuf Technol, Vol. 14, pp.549
554.
M
Khajavi, 200
06 Optimization of welding
[6] Mostafa, N.B and M.N.,
parameteers for weld penettration in FCAW, Journal of Achiievements in
Materialss and Manufacturiing Engineering.V
Vol. 16, pp.132 1338.
[7] Farh
had Kolahan and Mehdi Heidari, 2010. A new approach
a
for
predictin
ng and optimizing weld bead geomeetry in GMAW, International
I

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OnlineJournal)Volume2,Issue2,MarchApril,2015.ISSN:23497173(Online).

Journal of Mechanical Systems Science and Engineering, Vol. 2, pp.138

142.
[8] Ronay. B, 1960, The importance of polarity in arc welding, Welding
Engineer, Vol. 45, No. 3, pp. 3233.
[9] Utkarsh, S., Neel, P., Mahajan, T. 2014 Experimental Investigation of
MIG Welding for ST-37 Using Design of Experiment. International
Journal of Science and Research Publications, Volume 4, Issue 5, (May
2014) ISSN 2250-3153.
[10] P K Palani, Dr N Murugan, Modeling of Heat Input in Stainless
Steel Cladding using Taguchis Design of Experiments IE(I) JournalMC, Vol. 87, January 2.
[11] Oladele, I.O., Omotoyimbo, Adewuyi. 2009. Study of the effect of
welded joints on the mechanical properties of Wrought aluminum alloy,
The Pacific journal of science and Technology, Vol 10 (Nov 2009) pp
120-125.
[12] Latfe Y,Zedan , Ahmed F, 2010. State some mechanical properties
for Al-Alloy welded by seam welding Technoque, Diyala Journal of
Engineering Sciences, Vol. 03, No. 01, June 2010.
[13] Rakesh Sharma, Jagdeep Singh, 2014. Parametric Optimization of
MIG Welding for MS 5986 Fe 410 using Taguchi Method,Int. Journal of
Applied Sciences and Engineering Research, Vol. 3, Issue 3, 2014.
[14] P.Sathiya, S.Aravindan, P.M. Ajith, B.Arivazhagan, A. Noorul Haq,
2010 Microstructural characteristics on bead on plate welding of AISI
904 L super austenitic stainless steel using Gas metal arc welding
process,International Journal of Engineering, Science and Technology
Vol. 2, No. 6, 2010, pp. 189-199.

Mrs.R.Sridevi,(B.E).,
Department
of
Mechanical
engineering., Nadar Saraswathi College of Engineering and
Technology., Theni. She had published one paper in
refereed International Journal and Conference.

Mr.R.Ahamed Meeran, B.E., (M.E)., obtained his Bachelor

Degree in Mechanical Engineering in Nehru Institude of
Engineering and Technology, Coimbature.and Master
Degree in Manufacturing Engineering from Mother Terasa
College of Engineering and Technology,Pudukottai. He
had published two paper in refereed International Journal
and Conferences.

Biography

Dr. K.Chandrasekaran, B.E., M.E., PhD, MISTE, obtained

Mr.R.Sakthivel,(B.E)., Department of
Mechanical engineering., Nadar Saraswathi College of
Engineering and Technology., Theni. He had published one
paper in refereed International Journal and Conference.

his Bachelor Degree in Mechanical Engineering and

Master Degree in Manufacturing Engineering from Anna
University Chennai and Anna University of Technology
Tiruchirappalli. He completed his PhD in the area of
Manufacturing Engineering and Optimization from Anna
University, Chennai. Now he is working as an Assistant
Professor in Nadar Saraswathi College of Engineering
College, Theni. He had published number of papers in
refereed International Journals and Conferences.
_______________________________________________

Mr.P.Venkadeshwaran,(B.E)., Department of Mechanical

engineering., Nadar Saraswathi College of Engineering and
Technology., Theni. He had published one paper in
refereed International Journal and Conference.

Authors Address:
1

Department of Mechanical Engineering, Nadar

Saraswathi College of Engineering and Technology,
Theni, Tamilnadu, India.
*
Corresponding
Author
Email
ID:
sakthi.rajen71@gmail.com

___________________________________________

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