Methodology for development of welding procedures and empirical weld process models based on principal component analysis techniques

AbstractWith the increased automation of welding processes, there is a necessity for experimental design techniques that will permit rapid and efficient definition of the range of welding process parameters that may be used to produce acceptable welds for each new application. Such techniques are also required during development of empirical weld process models. In the present study, an experimental design technique based on principal component analysis (PCA) has been developed and shown to be more efficient than the traditional fractional factorial approach to experiment design, weld procedure development, and development of weld process models. Gas tungsten arc (GTA) welding of corner joint sheet steel was selected to exemplify the application of the technique. The boundary of a three­dimensional domain of weld process parameters (welding current, speed, and electrode gap) which could be used to produce acceptable welds when using either flush or edge touch corner joint configurations was satisfactorily...