Modeling and simulation of wire feed rate for steady current and pulsed current gas metal arc welding using 317L flux cored wire

2006 ◽  
Vol 34 (11-12) ◽  
pp. 1111-1119 ◽  
Author(s):  
P. K. Palani ◽  
N. Murugan
Keyword(s):  
Modeling And Simulation ◽  
Feed Rate ◽  
Arc Welding ◽  
Gas Metal Arc Welding ◽  
Pulsed Current ◽  
Cored Wire ◽  
Steady Current ◽  
Metal Arc Welding ◽  
Wire Feed

Static Tensile Strength and Process Optimization of Gas Metal Arc Welding (GMAW) for 1.5 mm Electro-Galvanized Transformation Induced Plasticity 780 (TRIP780) Steel Joint for Automotive Body Structural Applications

2009 ◽  
Author(s):  
Ramakrishna Koganti ◽  
Cindy Jiang ◽  
Chris Karas
Keyword(s):  
Tensile Strength ◽  
Feed Rate ◽  
Arc Welding ◽  
Gas Metal Arc Welding ◽  
Lap Joint ◽  
Transformation Induced Plasticity ◽  
Metal Arc Welding ◽  
Static Tensile ◽  
The Wire ◽  
Wire Feed

With the increasing demand for safety, energy saving and emission reduction, Advanced High Strength Steels (AHSS) have become very attractive steels for automobile makers. The usage of AHSS steels is projected to grow significantly in the next 5–10 years with new safety and fuel economy regulations. These new steels have significant manufacturing challenges, particularly for welding and stamping. Welding of AHSS remains one of the technical challenges in the successful application of AHSS in automobile structures due to Heat affected Zones (HAZ) at the weld joint. In this study Gas Metal Arc Welding (GMAW) of a lap joint configuration consisting of 1.5 mm Electro Galvanized (EG) Transformation Induced Plasticity 780 (TRIP780) to itself was investigated. The objective of the study was to understand the wire feed rate and torch speed influence on lap joint strength. Design of Experiments (DOE) was conducted to understand the wire feed and torch speed influence on tensile strength. Based on the statistical analysis, wire feed rate and torch speed were significant factors on static tensile strength. Two way interaction effect between wire feed and torch speed was significant. Metallurgical properties of the lap joints were evaluated using optical microscopy. No significant drop in hardness at HAZ, however, significant hardening was observed at the base metal and weld fillet interface.

Gas Metal Arc Welding (GMAW) Process Optimization of a 1.4 mm Uncoated Dual Phase 980 (DP980) Joint for Automotive Body Structural Applications

2010 ◽  
Author(s):  
Ramakrishna Koganti ◽  
Adrian Elliott ◽  
Cindy Jiang
Keyword(s):  
Tensile Strength ◽  
Feed Rate ◽  
Arc Welding ◽  
Gas Metal Arc Welding ◽  
Lap Joints ◽  
Lap Joint ◽  
Metal Arc Welding ◽  
Static Tensile ◽  
The Wire ◽  
Wire Feed

With the increasing demand for safety, energy saving and emission reduction, Advanced High Strength Steels (AHSS) have become very attractive steels for automobile makers. The usage of AHSS steels is projected to grow significantly in the next 5–10 years with new safety and fuel economy regulations. These new steels have significant manufacturing challenges, particularly for welding and stamping. Welding of AHSS remains one of the technical challenges in the successful application of AHSS in automobile structures due to heat-affected zone (HAZ) at the weld joint. In this study Gas Metal Arc Welding (GMAW) of a lap joint configuration consisting of 1.4 mm uncoated DP980 to itself was investigated. The objective of the study was to understand the wire feed rate and torch speed influence on lap joint tensile strength (static and fatigue). A two factor, two level, full factorial design of experiment (DOE) was conducted to understand the wire feed and torch speed influence on tensile and fatigue strength of the welded joints. In order to understand the curvature effect, a center point was also included in the experiment. Based on the statistical analysis, neither factor was significant on static tensile strength, however, a two way interaction between wire feed rate and torch speed was significant on static tensile strength. Metallurgical properties of the lap joints were evaluated using optical microscopy. A significant hardness drop of 40% was observed at the HAZ.

Gas Metal Arc Welding (GMAW) Process Optimization of 1.5 mm Uncoated Dual Phase 780 (DP780) Joint for Automotive Body Structural Applications

2009 ◽  
Author(s):  
Ramakrishna Koganti ◽  
Cindy Jiang ◽  
Chris Karas
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Feed Rate ◽  
Arc Welding ◽  
Gas Metal Arc Welding ◽  
Lap Joint ◽  
Weld Geometry ◽  
Metal Arc Welding ◽  
Static Tensile ◽  
Wire Feed

With the increasing demand for safety, energy saving and emission reduction, Advanced High Strength Steels (AHSS) have become very attractive steels for automobile makers. The usage of AHSS steels is projected to grow significantly in the next 5–10 years with new safety and fuel economy regulations. These new steels have significant manufacturing challenges, particularly for welding and stamping. Welding of AHSS remains one of the technical challenges in the successful application of AHSS in automobile structures due to heat-affected zone (HAZ) at the weld joint. In this study Gas Metal Arc Welding (GMAW) of a lap joint configuration consisting of 1.5 mm uncoated DP780 to itself was investigated. The objective of the study was to understand the wire feed rate (WFR) and torch (or robot) speed (TS) influence on lap joint tensile strength (static and fatigue). A two factor, two level, full factorial design of experiment (DOE) was conducted to understand the wire feed and torch speed influence on tensile and fatigue strength of the welded joints. In order to understand the curvature effect, center point was also considered in the experiment. Based on the statistical analysis both factors are significant on static tensile strength and two way interaction between wire feed rate and torch speed was also significant on static tensile strength. Wire feed rate was the common significant factor on all three fatigue load conditions (1200 lbf, 1500 lbf and 1900 lbf). Metallurgical properties of the lap joints were evaluated using optical microscopy. Significant hardness drop of 25% was observed at the HAZ. To understand the influence of weld parameters and weld geometry on mechanical properties, correlation analysis was conducted among weld heat input parameters, weld geometry and mechanical properties (both static and fatigue loads).

The Influence of Gas Metal Arc Welding Parameters on the Carbon Steel ss400 Grade by Using 23 Factorial Design

2011 ◽  
Vol 341-342 ◽  
pp. 11-15
Author(s):  
Prachya Peasura ◽  
Mongkol Chaisri
Keyword(s):  
Weld Metal ◽  
Feed Rate ◽  
Arc Welding ◽  
Gas Metal Arc Welding ◽  
Welding Process ◽  
Travel Speed ◽  
Factors Affecting ◽  
Metal Arc Welding ◽  
Arc Welding Process ◽  
Wire Feed

The experimental observation reveals that the influence of gas metal arc welding process on physical properties. The specimen was carbon steel ss400 grade sheet of 6 mm. The experiments with 23 factorial design. The factors used in this study are voltage at 20 and 23 V, travel speed at 5 and 7 mm/sec and wire feed rate were set at 80 and 110 mm/sec. The welded specimens were tested by penetration, width of weld metal and high of weld metal. The result showed that the voltage, travel speed and wire feed rate had interaction on penetration, width of weld metal and high of weld metal at 95% confidential (P value < 0.05). Factors affecting the penetration are the most voltage of 23 V, travel speed 7 mm/sec and wire feed rate 110 mm/sec. were penetration of 31.68 mm. The width of weld metal was most at 9.9 mm. on voltage of 23 V, travel speed 5 mm/sec and wire feed rate 110 mm/sec. The factors affecting the high of weld metal are most voltage of 20 V, travel speed 5 mm/sec and wire feed rate 110 mm/sec. were penetration of 4.51 mm. This research can bring information to the foundation in choosing the appropriate parameters to gas metal arc welding process.

Gas Metal Arc Welding (GMAW) Process Optimization of 2.0 mm Uncoated Boron Steel to 1.0 mm Usibor® 1500 P Steel Joint for Automotive Body Structural Applications

2010 ◽  
Author(s):  
Ramakrishna Koganti ◽  
Adrian Elliott
Keyword(s):  
Tensile Strength ◽  
Feed Rate ◽  
Arc Welding ◽  
Gas Metal Arc Welding ◽  
Travel Speed ◽  
Lap Joints ◽  
Boron Steel ◽  
Lap Joint ◽  
Metal Arc Welding ◽  
Wire Feed

With the increasing demand for safety, energy saving and emission reduction, Advanced High Strength Steels (AHSS) have become very attractive steels for automobile makers. The usage of AHSS steels is projected to grow significantly in the next 5–10 years with new safety and fuel economy regulations. These new steels have significant manufacturing challenges, particularly for welding and stamping. Welding of AHSS remains one of the technical challenges in the successful application of AHSS in automobile structures due to heat affected zones (HAZ) at the weld joint. In this study, Gas Metal Arc Welding (GMAW) of a lap joint configuration consisting of 2.0 mm uncoated boron steel and 1.0 mm Usibor® 1500 steel was investigated. The objective of the study was to understand the wire feed rate (WFR) and torch (or robot) travel speed (TTS) influence on lap joint tensile strength. Design of Experiments (DOE) methodology was used to understand the process parameter influence on the joint strength. Based on the statistical analysis, wire feed rate and torch travel speed were significant factors on static tensile strength. The interaction effect between wire feed rate and torch travel speed was not significant. Metallurgical properties of the lap joints were evaluated using optical microscopy. Significant drops in hardness at the HAZ were observed on both Usibor® 1500 P and boron steels.

Determination of Equilibrium Wire Feed Speeds for a Stable GMAW Process

2008 ◽  
Author(s):  
Z. H. Rao ◽  
J. Hu ◽  
S. M. Liao ◽  
H. L. Tsai
Keyword(s):  
Arc Welding ◽  
Gas Metal Arc Welding ◽  
Published Data ◽  
Trial And Error ◽  
Electrode Diameter ◽  
Current Electrode ◽  
Electrode Wire ◽  
Metal Arc Welding ◽  
Wire Feed

In gas metal arc welding (GMAW), for given welding conditions (e.g., current, electrode diameter, electrode material, etc.), the consumable electrode wire must be fed in such a speed that it dynamically balances the electrode melting speed in order to achieve a stable welding. In this article, a comprehensive model for GMAW was developed to study the interplay between the transport phenomena including the electrode melting and plasma arc, and the dynamically equilibrium wire feed speeds (WFSs) under different welding conditions. The predicted WFSs are in excellent agreement with published data that were obtained through the trial-and-error procedure.

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