Multi-Objective Process Optimization of Pulsed Plasma Arc Welding SS400 Steel Pipe with Foamed Aluminum Liner

Abstract

Principal component analysis (PCA) coupled with Taguchi methods are employed in the study for developing multiple quality characteristics optimization of pulsed plasma arc welding SS400 steel pipe with foamed aluminum liner (SPFAL). The quality characteristics investigated are the micro-hardness, the compression strength, and the bending strength of the weldments. Eight control factors selected are the tip aperture (Factor A), plasma base current (Factor B), plasma pulse current (Factor C), duty cycle (Factor D), pulse frequency (Factor E), shielding gas (Factor F), plasma gas (Factor G), and welding velocity (Factor H), respectively. It is shown by the experimental results that the optimal parameter combination of the pulsed plasma arc welding process is A1 (tip aperture: Ø1.5mm), B3 (plasma base current: 30A), C3 (plasma pulse current: 100A), D2 (duty cycle: 50%), E3 (pulse frequency: 300Hz), F2 (shielding gas: 14L/min), G3 (plasma gas: 0.4L/min), and H2 (welding velocity: 4RPM). Moreover, it is ascertained from the analysis of variance (ANOVA) results that plasma base current (B), plasma pulse current (C), duty cycle (D), and welding velocity (H) are the most important control factors in the process design, and thus strict control must be applied to them. They account for 75.02% of the total variance. The experimental results likewise show that the best process design could indeed enhance the multiple quality characteristics of the pulsed plasma arc welded SPFAL as 3020kgf of the bending strength, 13650kgf of the compression strength, and 180.4Hv of the hardness, respectively.

Study Computational Simulation and Experimental of Butt-Joint by Visual-Weld Software and MIG Welding Process

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Optimization of vacuum brazing process parameters in AA6061 using Taguchi method

“…While many factors affect the mechanical properties of aluminum alloy, the Taguchi method can optimize the process parameters of vacuum brazing, explaining its widespread use among industrial engineers. The welding and brazing parameters are optimized by Taguchi method in many literatures, such as brazing (Muangsong et al, 2013), friction stir welding (Koilraj et al, 2012;Shojaeefard et al, 2013), tungsten inert gas welding (Juang and Tarng, 2002), laser hybrid welding (Song et al, 2008), and pulsed plasma arc welding (Shih et al, 2012).…”

An Investigation of the Microstructure of an Intermetallic Layer in Welding Aluminum Alloys to Steel by MIG Process

“…Aluminum alloys are widely applied in the shipbuilding, aerospace, and automotive industries, as well as many other areas, because of their numerous advantages [ 1 , 2 ]. Steel, however, is used mostly in the manufacturing industry and in steel structures [ 3 , 4 ]. Combining these two materials can reduce both the time and cost of manufacturing, but it has been found that diffusion at the welds negatively affects weld quality.…”