Optimization of Double Pulsed Gas Metal Arc Welding Process Parameters for Joining Dissimilar Metal Based Materials by Using Taguchi Method
Project no. 29555 · Status: Kapanmış · 2023
Summary
<p>Double pulsed gas metal arc welding (DP-GMAW) method is widely used, particularly for joining thin materials, due to its advantages such as low heat input, high welding speed, and deep penetration. This welding method involves several parameters, including wire feed speed, voltage, peak current, base current, pulse frequency, and thermal pulse frequency. Optimizing these parameters, considering the physical and chemical properties of the materials to be joined, is essential for improving the mechanical properties of the weld joint and minimizing structural changes that may occur due to heat-affected zones.</p><p>In this research, low-carbon steel materials were joined in the preliminary study, while low-carbon steel and stainless steel materials were joined in the main study by DP-GMAW method. The wire feed speed, pulse current, and frequency parameters were optimized using the Taguchi method with an L9 orthogonal array. The effects of these parameters were evaluated through analysis of variance (ANOVA), and the optimal welding parameters were determined.</p><p>During the preliminary study, based on the results of the tensile tests, the optimal parameters for wire feed speed, pulse current, and frequency were determined to be 6.0m/min, -3%, and 3Hz, respectively. According to the ANOVA results, the wire feed speed was found to have the greatest impact on tensile strength when joining low-carbon steel materials using DP-GMAW.</p><p>In the main study, where different materials were joined, welding performance was evaluated through mechanical tests and macro/microstructure analyses. Based on the optimization results from data obtained from notched tensile test and Charpy tests, the optimal parameters for weld strength were found to be a wire feed speed of 8.0 m/min, -5% pulse current, and 6 Hz frequency. For weld toughness, the optimal parameters were determined as 8.0m/min wire feed speed, +5% pulse current, and 4Hz frequency. The ANOVA results indicated that pulse current had the greatest influence on welding performance when joining low-carbon steel and stainless steel materials using DP-GMAW.</p><p>According to the results, Taguchi design methodology significantly enhances process efficiency while reducing time and resource consumption in the optimization of DP-GMAW process parameters.</p>