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Parameter optimizations of GMAW process for dissimilar steel welding

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Abstract

When the welding materials, joint configuration, welding variables, and level settings of the welding parameters are not suitable and appropriate, the weld bead does not achieve optimum weld strength and ductility, resulting in damage and broken down on the welded joint when load/pressure is applied. The goal of this study is to present optimal process parameters for attempting to improve the mechanical properties of the weld joint. The experimental analysis methodology was used in this study. The goal of this study is to enhance welding process variables for dissimilar steel metal joints made of duplex stainless steel (DSS) to ASTM/UNS S32205 and erosional steel CORTEN-A to ASTM A242. Such a dissimilar metal joint finds use in the transportation sector, particularly in the construction of rail cars. The square butt joint between two 2-mm-thick sheets was investigated using the gas metal arc welding (GMAW) process with CO2 as the shielding gas and flux cored wire of grade 309L as the filler material. The L9 Taguchi array was used to optimize the tensile strength of the resulting weld joint, which was the desired quality characteristic. GMAW process parameters such as voltage, wire feed rate, and welding speed are optimized at three levels. Using ANOVA, the effects of each factor have been studied. It was found that the ideal set of parameters exists, and that the voltage is the most crucial factor. A confirmation test was performed to validate the results, and it was accompanied by a figure and tables.

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Acknowledgements

The authors are appreciative that my family provided financial support for this research. Additionally, I would like to thank the Mizan-Tepi University Mechanical Department for allowing me to use their welding equipment.

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Authors and Affiliations

  1. Mechanical Engineering Department, Mizan-Teppi University, Teppi Campus, Ethiopia

    Fasil Kebede Tesfaye

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  1. Fasil Kebede Tesfaye
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GT conducted a review, experimental result and data, and analyzed theoretical data. The author, Fasil Kebede Tesfaye, provided comments and checked the paper’s quality.

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Correspondence to Fasil Kebede Tesfaye.

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Tesfaye, F.K. Parameter optimizations of GMAW process for dissimilar steel welding. Int J Adv Manuf Technol 126, 4513–4520 (2023). https://doi.org/10.1007/s00170-023-11356-7

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  • DOI: https://doi.org/10.1007/s00170-023-11356-7

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