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2nd International Conference on Materials Manufacturing and Design Engineering
2nd International Conference on Materials Manufacturing and Design Engineering
Optimization of Activated Tungsten Inert Gas Welding of 304L
Optimization of Activated Tungsten Inert Gas Welding of 304L
Austenitic
Manufacturing Engineering Society Stainless Steel
Austenitic Stainless
International Steel
Conference
2017, Vigo (Pontevedra), Spain
2017, MESIC 2017, 28-30 June
Sanket C. Bodkheaa*, Dhananjay R. Dolasbb
Sanket C. Bodkhe *, Dhananjay R. Dolas
Costing models forDepartment
P.G. student, a
capacity
b
optimization
of Mechanical in Industry
Engineering, MGM’s JNEC, Aurangabad, (MS),4.0:
India Trade-off
Department
P.G. student, a
of Mechanical
Department Engineering,
of Mechanical MGM’sMGM’s
Engineering, JNEC, JNEC,
Aurangabad, (MS), India
Aurangabad, (MS), India
between used
Department b
capacity
of Mechanical and
Engineering, operational
MGM’s efficiency
JNEC, Aurangabad, (MS), India

Abstract A. Santana , P. Afonso , A. Zanin , R. Wernke

a a,* b b

Abstract a
University of Minho, 4800-058 Guimarães, Portugal
The objective of the present investigation isb to find the optimal set of process parameters to achieve higher depth of penetration
Unochapecó, 89809-000 Chapecó, SC, Brazil
(DOP)
The objective of the present investigation is (SS)
in A-TIG welding of stainless steel alloy
to find the 304L.
optimalInput
set ofparameters selected for
process parameters experiments
to achieve were
higher depthcurrent, welding
of penetration
speed and
(DOP) arc gapwelding
in A-TIG and design of experiments
of stainless wasalloy
steel (SS) carried out Input
304L. using parameters
central composite
selecteddesign of response were
for experiments surface methodology.
current, welding
Autogenous
speed and arcbead gapon
andplate
designwelds in the presence
of experiments wasofcarried
mono-component flux were
out using central made design
composite on SS 304L plates surface
of response of thickness 6 mm to
methodology.
generate
Autogenousdatabead
and to
onstudy
plate the influence
welds in the of input variables
presence on DOP. ANOVA
of mono-component was made
flux were carriedonout
SSto304L
determine
plates the significance
of thickness of the
6 mm to
Abstract
process
generate parameters
data and to and
studyit the
wasinfluence
found that welding
of input current
variables on is the ANOVA
DOP. most significant input
was carried outvariable influencing
to determine DOP. A of
the significance linear
the
regression equation and
process parameters was developed
it was found to predict DOP for
that welding a given
current set most
is the of input process parameters.
significant input variable Then, desirability
influencing DOP.approach of
A linear
Under
RSM is the
used
regression concept of developed
for numerical
equation was "Industry to4.0",
optimization production
to obtain
predict DOP for a processes
maximum depthsetofof
given will
inputbeprocess
penetration. pushed to be increasingly
parameters. interconnected,
Then, desirability approach of
information
RSM is used for based on a real
numerical time basis
optimization and, necessarily,
to obtain maximum depth much more efficient. In this context, capacity optimization
of penetration.
goes beyond
© 2017 the traditional
The Authors. Published aim byof capacity maximization, contributing also for organization’s profitability and value.
Elsevier B.V.
©
© 2018
2017The
Indeed, The Authors.
leanAuthors. Published
Published
management byby
and Elsevier B.V.B.V.
Elsevier
continuous improvement
Peer-review under responsibility of the scientific committee approaches suggest capacity
of the 2nd International optimization
Conference instead of
on Materials
Peer-review under responsibility of the scientific committee of the 2nd International Conference on Materials Manufacturing and
Peer-review
Manufacturing
maximization. under
Design Engineering. and
The responsibility
Design
study of of the
Engineering.
capacity scientific
optimization committee
and of
costing the 2nd
models International
is an importantConference
research on Materials
topic that deserves
Manufacturing
contributions andboth
from Designthe Engineering.
practical and theoretical perspectives. This paper presents and discusses a mathematical
Keywords:
model forA-Tungsten
capacity inert gas welding;based
management response
onsurface methodology;
different costing optimization;
models (ABC desirability approach; SSA304L
and TDABC). generic model has been
Keywords: A-Tungsten inert gas welding; response surface methodology; optimization; desirability approach; SS 304L
developed and it was used to analyze idle capacity and to design strategies towards the maximization of organization’s
value. The trade-off capacity maximization vs operational efficiency is highlighted and it is shown that capacity
1. Introduction
optimization might hide operational inefficiency.
1. Introduction
© 2017 The Authors. Published by Elsevier B.V.
Out of all
Peer-review undermaterials, steel of
responsibility is the
thescientific
most frequently
committeeused
of thefor different applications.
Manufacturing It should
Engineering Society be expected
International that this
Conference
Out of
metal,
2017. duealltomaterials, steel is the
its properties, willmost
remainfrequently useduseful
the most for different applications.
and most It should
frequently be expected
used material for that this
product
metal, due to As
manufacturing. its austenitic
properties, will remain
stainless thegood
steel have mostresistance
useful and most frequently
to corrosion and better used material
mechanical for product
properties, they
manufacturing.
are extensively
Keywords: As austenitic
used
Cost Models; stainless
inTDABC;
ABC; steel
high performance have good
pressure
Capacity Management; resistance to corrosion
vessels,Operational
Idle Capacity; and
medical Efficiency better mechanical properties,
industry, nuclear and chemical process they
are extensively used in high performance pressure vessels, medical industry, nuclear and chemical process

1. Introduction
* Corresponding author. Tel.: +919421885550.
E-mail
*The address:2bsanket@gmail.com
Corresponding
cost author.
of idle Tel.: +919421885550.
capacity is a fundamental information for companies and their management of extreme importance
E-mail address:2bsanket@gmail.com
in modern production systems. In general, it is defined as unused capacity or production potential and can be measured
2351-9789© 2017 The Authors. Published by Elsevier B.V.
in several ways:
Peer-review under
tons of production,
responsibility
available
of thebyscientific
hours of manufacturing, etc. The management of the idle capacity
committee of the 2nd International Conference on Materials Manufacturing and
2351-9789© 2017 The Authors. Published Elsevier B.V.
* Paulo Afonso. Tel.:
Design Engineering.
Peer-review +351 253 510 761; fax: +351 253 604
under responsibility of the scientific committee 741 of the 2nd International Conference on Materials Manufacturing and
E-mail address:
Design Engineering. psafonso@dps.uminho.pt

2351-9789 © 2017 The Authors. Published by Elsevier B.V.

Peer-review
2351-9789 © under
2018responsibility
The Authors. of the scientificbycommittee
Published Elsevier of the Manufacturing Engineering Society International Conference 2017.
B.V.
Peer-review under responsibility of the scientific committee of the 2nd International Conference on Materials Manufacturing and
Design Engineering.
10.1016/j.promfg.2018.02.041
278 Sanket C. Bodkhe et al. / Procedia Manufacturing 20 (2018) 277–282
2 Author name / Procedia Manufacturing 00 (2017) 000–000

industries. AISI 304L is widely used among different grades of stainless steels because of its good resistance to
corrosion and great formability. Although, for the several last decades, we have been intensively developing modern
welding procedures, such as laser, electron beam and hybrid, their widespread use has yet to be seen. Thanks to its
high quality welds, mobility, simplicity and low equipment costs, TIG welding has remained dominant. In addition,
the TIG welding technique can be used for all welding positions and generally produces a smooth, clean weld [1-3].
However the potential problems of TIG welding process lie in the limited thickness of material (limited to 3mm)
which can be welded in a single-pass leading to low productivity [4]. Low productivity results from a combination of
the low welding speed and the multi-pass welding procedure for thick section plated or heavy wall pipe materials. If
the welding current is increased in an attempt to increase the penetration, the weld becomes excessively wide with
proportionally little gain in the penetration. Additional costs are incurred through edge preparation and substantially
longer time because several passes with filler metal are required to fill the groove joints [5].
Improvements in the penetration have long been sought in many arc-welding processes. One of the most notable
techniques is the use of activating flux in TIG welding process. Activated tungsten inert gas (A-TIG) welding
process that increases the penetration was first proposed by Paton Electric Welding Institute in the 1960s. Activating
flux is a mixture of inorganic material suspended in a volatile medium. A thin layer of flux is applied on the surface
of the joint to be welded by brush before welding [6]. A-TIG technique makes it possible to intensify the
conventional TIG practices for joining the thickness of 8-10 mm by single-pass full penetration welds, with no edge
preparation, instead of multi-pass procedures. In fact, the penetration capability is up to 300% compared with the
conventional TIG welding process [7]. Several mechanisms have been proposed for the improvement in the DOP in
A-TIG welding. One of them is arc constriction put forth by Howse and Lucas which proposes that the electrons
present in the ionized vapours of the flux ingredients are captured at the periphery of the arc and, thus, current flow
is restricted to the centre of the arc. Thus, the constricted arc leads to formation of narrow but deeper weld pool [8].
The other mechanism proposed by Heiple and Roper suggests that the positive surface tension gradient generated in
the molten weld metal by the addition of elements such as oxygen which can reverse the surface tension gradient
produces a strong inward fluid flow; this reversed mode of Marangoni convection current transfers heat towards the
root of the weld pool resulting in narrower and deeper weld [9].

2. Response surface methodology

Response surface methodology (RSM) is a collection of mathematical and statistical techniques for empirical
model building. By careful design of experiments, the objective is to optimize a response (output variable) which is
influenced by several independent variables (input variables). An experiment is a series of tests, called runs, in
which changes are made in the input variables in order to identify the reasons for changes in the output response.
RSM is very valuable for the modelling, optimization and analysis of problems in which a response of significance is
influenced by a number of process parameters called variables, and the objective is to optimize the response. RSM is
defined to identify the relationships between the controllable input welding variables and the desired responses.
Generally, the objective is to estimate the input process parameters at which the responses achieved will be
optimum. The optimum can be either a minimum or maximum of a certain function in terms of the input process
parameters [10].

3. Experimental work

A-TIG welding process input parameters which influence the weld bead geometry were identified from the
literature. Table 1 shows the chemical composition of SS 304L.

Table 1: Chemical composition of SS 304L

Alloy element C Si Mn P S Cr Ni Fe

SS 304L 0.06 0.42 1.89 0.032 0.014 18.67 8.53 Balance

Sample of 150mm×60mm×6mm size has been used as work piece material for the experiment. Each specimen
surface was roughly polished with silicon carbide abrasive paper of 400 grit size and then cleaned by acetone to
 Sanket C. Bodkhe et al. / Procedia Manufacturing 20 (2018) 277–282 279
Author name / Procedia Manufacturing00 (2017) 000–000 3

avoid any source of contamination like scale, dust, oil, moisture rust etc prior to the experimental work. Oxide flux
powder of SiO2 and acetone are mixed uniformly. This paint like mixture is brushed on plates before welding. A-
TIG bead-on-plate welds were made on plates in a single pass. A 2% thoriated tungsten electrode of diameter 2.4mm
with 60° tip angle and argon as shielding gas with a flow rate of 10 L/min was used. Table 2 shows process control
variables and their levels. The ranges and levels of control variables are fixed based on the specification of welding
machine, thickness of the material and available literature.
The experiments were performed as per the design matrix to study the effect of A-TIG welding process
parameters on the DOP. The number of experiments conducted in the present case was 20 and the number of
welding process parameters considered were three. The design matrix was developed as per rotatable central
composite design of RSM. Three factors were varied at three levels.

Table 2: Process control variables and their levels

Parameters Original Value Unit
Low Medium High
Electrode gap 1 2 3 mm
Torch speed 60 80 100 mm/min
Current 150 175 200 A

The experiments were performed as per the design matrix to study the effect of A-TIG welding process
parameters on the DOP. In order to measure the DOP, the 20 welded samples were cut perpendicular to the direction
of welding. The samples were polished and etched to view the macrostructure of the weld samples. Table 3 shows
the experimental results.

Table 3: Design matrix and experimental results

Process parameters Response

Run Order Current (A) Speed (mm/min) Gap (mm) Depth of penetration (mm)

1 200 100 1 5.19

2 175 80 2 4.62
3 150 60 3 3.81
4 175 80 2 4.51
5 150 100 1 3.77
6 150 60 1 4.13
7 175 80 1 4.80
8 175 60 2 4.76
9 175 100 2 4.27
10 175 80 2 4.45
11 200 60 1 6.00
12 150 100 3 3.63
13 200 60 3 5.71
14 150 80 2 3.74
15 175 80 2 4.72
16 200 80 2 5.24
17 200 100 3 4.93
18 175 80 2 4. 62
19 175 80 2 4.69
20 175 80 3 4.34
280 Sanket C. Bodkhe et al. / Procedia Manufacturing 20 (2018) 277–282
4 Author name / Procedia Manufacturing 00 (2017) 000–000

4. Results and discussion

Design expert V10 (trial version) software was used for the statistical analysis of A-TIG welding of SS 304L
process parameters. The adequacy of the model is tested using the sequential F-test, lack-of-fit test, and the analysis
of variance (ANOVA) technique to obtain the best fit model. In this work, RSM was used to develop mathematical
relationships between the welding variables and the response for predicting the desired optimum DOP.

4.1 ANOVA

ANOVA was performed for estimating the significance of the model at 95% significance level. A model is
considered to be significant if the significance probability value (p value) is less than 0.0500. The objective of
ANOVA is to investigate whether the A-TIG welding process parameters have significant effects on the DOP and to
recognize whether the model developed is significant. The ANOVA for DOP is shown in Table 4. The lack of fit
value of 0.2427 implies that it is not significant. The adequacy measures adjusted R 2 is close to 1, as it is desirable,
which shows the adequacy of the model.

Table 4: ANOVA analysis of the depth of penetration

Source Sum of squares df Mean square F-value p-Value Prob.> F Percentage Contribution

Model 7.29 3 2.43 137.65 <0.0001 Significant

Current 6.38 1 6.38 361.81 <0.0001 87.51
Torch speed 0. 69 1 0. 69 38.90 <0.0001 9.46
Arc gap 0.22 1 0.22 12.25 0.0030 3.01
Residual 0.28 16 0.018
Lack of fit 0.23 11 0.021 1.93 0.2427 Not significant
Pure error 0.054 5 0.011
Cor Total 7.57 19
Std. Dev. 0.13 R2 0.9627
Mean 4.0 Adj. R2 0.9557
2
C.V. % 2.89 Pred. R 0.9280
PRESS 0.54 Adeq. Precisor 40. 670

The percentage contribution of parameters on the DOP is shown in Table 4. Current has more percentage
contribution on DOP (87.51%) followed by torch speed (9.46%). Therefore, current is the significant process
parameter influencing the DOP during A-TIG welding of SS 304L.

4.2 Regression equation

Regression analysis generates an equation to describe the statistical relationship between the input factors and the
response variable and to predict new observations. This regression equation is used to predict the depth of
penetration value from any random value of current, torch speed and arc gap.

DOP  0.34550  0.03190Current   0.013100Speed   0.14700 Arcgap  (1)

5. Optimization using desirability approach in RSM

5.1 Numerical optimization

The optimization method is carried out using design expert software, where the scale of desirability function
ranges between d=0, which implies that the response is completely unacceptable, and d=1, which implies that the
 Sanket C. Bodkhe et al. / Procedia Manufacturing 20 (2018) 277–282 281
Author name / Procedia Manufacturing00 (2017) 000–000 5

response is more desirable. The goal of the response can be maximum, minimum, in the range, target and/or equal to
depending on the nature of the problem. The profile of the desirability function can be altered for response by the
weight field. Weights can be ranged from 0.1 to 10; a weight greater than 1 provides more emphasis to the goal,
weights less than 1 provide less importance. When the weight value is equal to one, the desirability function varies in
a linear mode. Each response can be assigned an importance, relative to the other responses. Importance varies from
the least important value of 1, indicated by (+), the most important value of 5, indicated by (+++++).Optimization of
process parameters in design expert software V10 finds for a combination of factor levels that concurrently satisfy
essential optimization criteria on each one of the response and process parameters [11]. During A-TIG welding of SS
304L, the main objective was to achieve maximum depth of penetration. Optimal solutions were generated based on
the criteria given in Table 5. RSM method provided 72 solutions in terms of process parameters for achieving
maximum DOP. 13 optimal solutions are given in Table 6.

Table 5: Optimization criteria

Process parameters and
Goal Lower limit Upper limit Lower weight Upper weight Importance
response

Current In range 150 200 1 1 3

Torch speed In range 60 100 1 1 3
Arc gap In range 1 3 1 1 3
DOP Maximize 3. 63 6 0.1 1 5

Table 6: Optimal solutions based on criteria

Number Current Torch speed Arc gap Depth of penetration Desirability

1 200 60.0221 1.00003 5.80027 0.991

2 198.065 60.0018 1.00002 5. 74264 0.989
3 199.999 60.0002 1. 64957 5.70899 0.987
4 199.999 60.0003 1.83947 5. 68106 0.986
5 200 73.9753 1.00003 5. 62142 0.983
6 194.22 60.0001 1.0001 5. 61975 0.983
7 199.999 60.0003 2.34626 5. 60657 0.982
8 200 78.3901 1.00006 5.56357 0.980
9 200 64.2421 2.33676 5.55242 0.979
10 199.415 60.003 2.99084 5.49314 0.976
11 200 84.4586 1.00013 5.48407 0.976
12 200 65.4249 2.99899 5.43957 0.973
13 200 71.7601 2.9995 5.35644 0.969

5.2 Confirmation test

The confirmation experiment was carried out for the optimal solution identified in the model for achieving the
maximum depth of penetration. From Table 5 it is clear that to achieve higher depth of penetration, the current value
must be higher and the torch speed must be maintained at lower value. Two sets of process parameters were selected
from the list of optimum solutions obtained for the validation experiments. Table 7 shows the result of confirmation
test. Percentage error for both tests was less than five percent. Additionally, two butt joints were made by
conventional TIG welding and by Activated-TIG welding from a combination of process parameters given in
experiment number one of confirmation tests. The ultimate tensile strength for joint made by conventional TIG
282 Sanket C. Bodkhe et al. / Procedia Manufacturing 20 (2018) 277–282
6 Author name / Procedia Manufacturing 00 (2017) 000–000

welding was 378MPa and for joint made by Activated-TIG welding was 438MPa. Results indicate that joints made
by Activated-TIG welding exhibit better tensile strength compared to conventional TIG welding.

Table 7: Confirmation test results

Sr. No. Parameters Depth of penetration (mm)
Current (A) Torch speed Electrode gap Actual value Predicted Percentage
(mm/min) (mm) value error
1. 200 60 1 6 5.79 3.50
2. 194 60 1 5.9 5.61 4.91

6. Conclusion
1. RSM can be effectively used for the investigation of multiple performance characteristics and optimization of
process parameters in A-TIG welding of SS 304L.
2. Investigation of process parameter such as welding current, torch speed and arc gap on depth of penetration in
A-TIG welding of SS 304L has been studied. All the three process parameters which include current, torch
speed and arc gap have been found to be significant in influencing the depth of penetration. From ANOVA
table, it is clear that all three process parameters are found to be significant with current the most significant
parameter.
3. Experimental results show that complete penetration of 6mm was possible to achieve at current value of 200A.
Conventional TIG welding with single pass is limited to a penetration capability of 3mm. The depth of
penetration is increased by about 200%. Therefore, for increase in penetration, the use of SiO 2 as activating
flux presents a satisfactory performance.
4. Regression equation generated is useful in predicting the depth of penetration for any random values of
welding current, torch speed and arc gap.

References

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