Experimental Investigation and Parametric Optimization of the Tungsten Inert Gas Welding Process Parameters of Dissimilar Metals

Abstract

Special attention is required when joining two materials with distinct chemical, physical and thermal properties in order to make the joint bond robust and rigid. The goal of this study was to see how significantly different tungsten inert gas (TIG) welding process parameters (welding current, gas flow rate, root gap, and filler materials) affect mechanical properties (tensile, hardness, and flexural strength), as well as the bead width and microstructural properties, of dissimilar welds In comparison to SS 316 and AISI 1020 low-carbon steel. TIG welding parameters were optimized in this study using a Taguchi-based desirability function analysis (DFA). From the experimental results, it was observed that welded samples employing ER-309L filler wires had a microstructure consisting of a delta ferrite network in an austenite matrix. The tensile strength experimental results revealed that welding current, followed by GFR, was a highly influential parameter on tensile strength. Weld metals had higher hardness and flexural strength than stainless steel and carbon steel base metals. This was supported by the fact that the results of our tests had hardness ratings greater than a base for the FZ and HAZ, and that no crack was observed in the weld metal following U-shape flexural bending. Welding current has a significant impact on the bead width of welded specimens, followed by root gap. Furthermore, the dissimilar welded sample responses were optimized with a composite desirability percentage improvement of 22.90% by using a parametric setting of (A2B4C4D2). Finally, the validation of the experiment was validated by our confirmation test results, which agreed with the predictive optimum parameter settings.

Exploring the Potential Application of an Innovative Post-Weld Finishing Method in Butt-Welded Joints of Stainless Steels and Aluminum Alloys

“…The study on the microstructure, residual stresses, and stress corrosion cracking resulting from repair welding on 304 stainless steel is detailed in reference [12]. Article [13] aimed to evaluate the impact of different parameters in the tungsten inert gas (TIG) welding process on mechanical properties, stitch width, and microstructural characteristics of welds compared to 316 steel. Reference [14] discusses diverse butt joints between 6061-T6 aluminum alloy and AISI 316 stainless steel fabricated through friction stir welding (FSW) with varying parameters.…”

Influence of Welding Parameters on Strength of Metal Inert Gas Welded Mild Steel Joints

“…In order to have good joint properties, it was important that the researchers ensure that the welds were free from defects. We build upon the work of [3], [28]by using grey-based Taguchi Orthogonal Array (L27) method to optimize parameters including preheat temperatures, welding current, gap distance, weld speed and post-weld temperatures for better weld quality. This is because L27 performs 27 experiments to determine the optimal parameters and has greater accuracy compared to L9.…”

“…Using a Taguchi L25 orthogonal array and desirability function analysis (DFA), [28] investigated the effects of welding current, gas flow rate, gap distance, and filler materials on the mechanical and microstructural properties of dissimilar welds of SS 316 and AISI 1020 low-carbon steels using tungsten inert gas (TIG) welding. The properties studied were tensile, hardness, and flexural strength, as well as the bead width of the welds.…”

Experimental Investigation and Parametric Optimization of Automated MIG welding Stainless Steel SS316 with Low Alloy Steel AISI 4140 on Mechanical Properties

“…The process can be used semi-automatically, automatically, or robotically; because of its ability to produce repeatable joints, the process has the potential to be used in mass production units. Automated MIG welding follows the same basic principle as manual or semi-automated MIG welding, which involves using a consumable wire electrode and a shielding gas to melt and join metals together at the weld joint [1][2][3][4]. The electrode wire's end is melted by the arc and then moved to the molten weld pool.…”