To study the effect of welding parameters on weld bead geometry in SAW welding process

A B ST R A C T In the present work, an effort has been made to investigate the effect of welding parameters on bead geometry. Mathematical models were developed by using 2- level half factorial technique to predict the bead geometry within the range of control parameters or operating variables for single wire submerged are welding. The models developed can be employed easily in automatic or robotic welding, in the form of program, for obtaining the desired high quality welds. Current, open circuit voltage, welding speed and nozzle-to-plate distance were taken as welding variables constant. The models were developed from the observed values, with the help of design matrix. It was found that penetration increases significantly with current, decreases with welding speed and remains unaffected by open circuit voltage & nozzle to plate distance. Reinforcement was found to increase with current and decrease with open circuit voltage, welding speed and there is no effect by nozzle to plate distance. Weld bead width was found to increase with open circuit voltage, decrease with welding speed; but ‘w’ increases with increase in nozzle to plate distance. The adequacies of the models were tested by use of analysis of variance technique and signification of coefficients was tested by student’s-test’. The combined and main effect of different parameters involved has been presented in graphical form.