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MATHEMATICAL MODELING OF HARDFACING LOW CARBON STEEL WITH CORROSIVE NICKEL BASED ALLOY BY GMAW By S. Santhosh (1066008)
Under the Guidance of Prof. C. Bhagyanathan AP/MFG Assistant Professor
INTRODUCTION
Corrosion and Wear are the major problems in metallic components. Wear occurs in the sliding contacts due to dynamic loading. Both has drastic effects on the applications and costs on metallic components.
PROBLEM IDENTIFICATION
Wear is the drastic effect on metal to metal contact parts so the life span of the part is short according to its service condition. Replacing the worn-out parts to new parts in all the time is not economic for industries. Most of the machine parts has weight to strength ration constrains within this limits the material property should be enhanced.
PROBLEM DEFINITION
To create mathematical model for bonding Chromium-Cobalt alloy with Low Carbon Steel for GMAW process To optimize GMAW process parameters Validate the result by applying conformity test, corrosion test and wear test.
METHODOLOGY
Problem Identification
Phase - I
Literature Survey
LITERATURE SURVEY
1Effect
Extended Abstract The defect free deposits can be made without any preheating by the GMAW process and the deposits has a more uniform. Key words GMAW, Microstructure, Stellite-6 Interception Study on the GMAW process
Extended Abstract Constant current characteristics were typically advantageous for automatic welding, to provide sufficient accuracy and repeatability in current level from weld to weld. Key words GMAW, GTAW, Accuracy, Repeatability Interception Power supply characteristics of GMAW process
Extended Abstract GMAW is the best suited for hardfacing small parts as it produces high quality deposits. Key words GMAW, Hardfacing, Quality Interception Study the importance of hardfacing
Extended Abstract Welding variables such as welding current, filler rod feed rate, welding speed and even current mode have effect on surfacing deposit irrespective of process. Key words Welding parameter Interception Study on effect of welding variables on deposit rate
PARAMETERS
PARAMETERS
Parameter
DOE MATRIX
Process variables Trail No. Arc Voltage (V) 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 -1 1 -1 1 -1 1 -1 1 -1 1 -1 1 -1 1 -1 1 Wire feed rate (F) -1 -1 1 1 -1 -1 1 1 -1 -1 1 1 -1 -1 1 1 Welding speed (S) -1 -1 -1 -1 1 1 1 1 -1 -1 -1 -1 1 1 1 1 Nozzle to plate distance (D) -1 -1 -1 -1 -1 -1 -1 -1 1 1 1 1 1 1 1 1
RESPONSE
Process variables Trail No. V 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 -1 1 -1 1 -1 1 -1 1 -1 1 -1 1 -1 1 -1 1 F -1 -1 1 1 -1 -1 1 1 -1 -1 1 1 -1 -1 1 1 S -1 -1 -1 -1 1 1 1 1 -1 -1 -1 -1 1 1 1 1 D -1 -1 -1 -1 -1 -1 -1 -1 1 1 1 1 1 1 1 1 BW 10.17 9.51 11.02 7.01 9.52 7.85 9.97 8.78 10.89 9.62 11.13 7.13 9.64 7.97 10.48 10.17 BH 3.50 4.40 3.95 3.19 2.74 3.64 3.19 4.10 3.65 4.55 4.10 3.34 2.89 3.79 3.34 3.50 BP 1.19 1.06 1.31 1.04 1.29 1.16 1.41 0.78 1.03 0.90 1.15 0.88 1.13 1.00 1.25 1.19 Di % 19.19 25.35 19.48 24.97 24.50 31.92 24.18 30.66 15.95 21.97 16.57 21.96 20.76 28.01 20.89 27.24 Bead parameters
MATHEMATICAL MODEL
The response function representing any weld bead dimension can be expressed as, Y = f (V, S, F, D) Where, Y = Response function. b0, bi = Regression co-efficient. Xi = Parameters or variables. K Y = b0 + bi Xi i=1
MATHEMATICAL MODEL
For four factors the selected polynomial (regression) equation could be expressed as: Y = S b0 + b1V + b2 F + + b4 D b3
REGRESSION COEFFICIENT
Value Coefficient Due to BW BH BP Dilution
b0
2.450
4.801
0.345
5.436
b1
Arc Voltage
0.204
0.0450
0.025
0.631
b2
0.240
0.1500
0.042
0.070
b3
Welding Speed
0.091
0.054
0.007
0.381
b4
0.482
0.303
0.32
6.725
Arc Voltage, Wire Feed Rate and Nozzle to Plate Distance shows an positive influence on the bead width. Welding Speed shows an negative influence on the bead width. From the positive influencers the Nozzle to Plate Distance Plays major role
Wire Feed Rate and Nozzle to Plate Distance shows an positive influence on the bead width. Welding Speed and Arc Voltage shows an negative influence on the bead width. From the positive influencers the Nozzle to Plate Distance Plays major role
Arc Voltage, Wire Feed Rate and Welding Speed shows an positive influence on the bead width. Nozzle to Plate Distance shows an negative influence on the bead width. From the positive influencers the Nozzle to Plate Distance Plays major role
Arc Voltage, and Welding Speed shows an positive influence on the bead width. Wire Feed Rate and Nozzle to Plate Distance shows an negative influence on the bead width. From the positive influencers the Nozzle to Plate Distance Plays major role
CONCLUSION
The primary objective of this dissertation is to develop mathematical models for improving the weld bead quality using GMAW process, for FW-2 hardfacing on low carbon valve. The mathematical models were developed using regression analysis and four factor two level design matrix is effectively used. Mathematical models were developed for the following responses like Bead Height (BH), Bead Reinforcement (R), and Bead Width (W), The responses were related with process parameters, Arc Voltage (V), Wire Feed Rate (F), Welding Speed (S) and Nozzle to Plate Distance (D). The Mathematical model indicates, the influence of Arc Voltage, Feed Rate, Welding Speed and Nozzle to Plate Distance on Bead Height, Bead Reinforcement and Bead Width
REFERENCES
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Albert S.K, Gowrisankar I, Seetharaman V, and Venkatesan S, Effect of Welding Parameters on the Microstructure of Stellite-6 Deposits, Proceeding of National Welding Seminar, IIW, Bangalore., Nov. 26-28, pp A1- A7. Dennis Destefan, Basics to know when choosing a GMAW and GTAW power source, Welding Journal, pp 67-72. Barr L.C. and Rogers C.E., Hardfacing Past, Present, Future, Welding Journal, pp 968-974. Foroulis Z.A, Guidelines for the selection of hardfacing alloys for Sliding Wear Resistance Application, TMS AIME, New York, pp. 203-218. Quaas J.F., Hardfacing International Welding Journal, pp.175-182.