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1 Journal of Achievements in Materials and Manufacturing Engineering

1 2006

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Optimisation of welding parameters for weld penetration in FCAWN

Mostafa N. B., Khajavi M. N.

Journal of Achievements in Materials and Manufacturing Engineering

2006

Vol. 16, nr 1-2

132--138

Purpose: This paper describes prediction of weld penetration as influenced by FCAW process parameters of welding current, arc voltage, nozzle-to-plate distance, electrode-to-work angle and welding speed. Optimization of these parameters to maximize weld penetration is also investigated. Design/methodology/approach: It deals with the statistical technique of central composite rotatable design to develop a mathematical model for predicting weld penetration as a function of welding process parameters. The constrained optimization method is then applied to this model to optimize process parameters for maximizing weld penetration. Findings: The result obtained from the developed model indicates that the model predicts the weld penetration adequately. The optimization result also shows that weld penetration attains its maximum value when welding current, arc voltage, nozzle-to-plate distance and electrode-to-work angle are maximum and welding speed is minimum. Research limitations/implications: The statistical technique of developing a model for prediction of weld penetration is valid only within the specified limits of welding process parameters and hence maximization of penetration is also valid within these limits. This technique can be modified to include other parameters such as plate thickness affecting penetration. Practical implications: The statistical method for modeling and the optimization method used have found increasing applications in a variety of fields for investigation because through these methods research becomes economical, fast and versatile. Originality/value: The methods described in this paper for weld penetration prediction and optimization can eliminate the need for performing experiments on the basis of the conventional trial and error method which is time consuming and economically not justifiable.