Abstract
The welding seams procedure is widely used in the manufacturing industries for intermediary steps of the steel production or joints of parts of several manufactured products such as automobile, ships and aircrafts. The weld seams can be produced through a number of different arc welding processes, but the comparison of two different welding processes for the production of a quality weld seam is not trivial, and a quantitative method, which gives comparable parameters, is necessary to be developed. In this work, a method is proposed for comparing between two welding processes through the statistical study of the effects that two welding energy levels have on the selected output variables of each one. A 22 full factorial design of experiment was applied. The process responses are one-dimensional weld bead geometry (penetration, width and reinforcement), two-dimensional weld bead geometry (penetration area and reinforcement area), dilution and weld bead microstructure. The statistical analyses showed that the methodology presented is capable of determining objective parameters (statistically based) which can be useful in comparing and selecting a suitable process for a specific application. The comparison of the results between fluxed core arc welding (FCAW) and shielded metal arc welding processes reveled that both produced weld seams with the same penetration. Therefore, in this study, it was recommended the selection of the FCAW process at low energy level, which was able to produce larger width weld seams and improved microstructure quality, saving 30% of the energy consumption.
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Abbreviations
- α :
-
Constant of proportionality for anode or cathode heating
- β :
-
Constant of proportionality for electrical resistance heating
- η :
-
Thermal efficiency factor
- A :
-
Reinforcement area
- B :
-
Penetration area
- CTWD:
-
Contact tip-to-work distance
- D :
-
Dilution
- DM:
-
Deposited metal
- DR:
-
Deposition rate
- E :
-
Welding energy
- E c :
-
Electrode composition
- E ex :
-
Electrode extension
- E fs :
-
Electrode feed speed
- E φ :
-
Electrode diameter
- H :
-
Heat input
- I :
-
Welding current
- L :
-
Arc length
- MR:
-
Melting rate
- MTM:
-
Metal transfer mode
- OF:
-
Operating factor
- P :
-
Penetration
- R :
-
Reinforcement
- S :
-
Travel speed
- SGc :
-
Shielding gas composition
- U :
-
Welding voltage
- U source :
-
Voltage set on power source
- W :
-
Width
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Acknowledgments
The authors thank the Laboratory of Materials Characterization of Federal Institute of Southeast of Minas Gerais State—IF Sudeste MG, and the Laboratory for Welding Process Optimization of Federal University of Juiz de Fora—UFJF, for providing laboratorial support. The authors also thank the ESAB Company in Brazil for the consumables supply. This work was supported by FAPEMIG (article publication) and UFJF (undergraduate research scholarship program). We specially thank Professor Américo Scotti (Federal University of Uberlândia) for discussions.
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Silva, G.C., de Castro, J.A., Filho, R.M.M. et al. Comparing two different arc welding processes through the welding energy: a selection analysis based on quality and energy consumption. J Braz. Soc. Mech. Sci. Eng. 41, 301 (2019). https://doi.org/10.1007/s40430-019-1804-x
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DOI: https://doi.org/10.1007/s40430-019-1804-x