Indian Institute of Technology Gandhinagar Department of Mechanical Engineering

ME311 Manufacturing Process Lab 15/10/2012 Submitted by : Kaushal Chavda 10003032 B.Tech , Mechanical, Semester # 05

Experiment: Gas Metal Arc Welding (GMAW)

Objective: To study the influence of process parameter on weld geometry and melting efficiency in
GMAW/MIG welding with DCEP polarity.

Apparatus:
1. 2. 3. 4. 5. 6. DC GMAW power source Electrode feeder and electrode wire spool Flexible air-cooled torch Inert gas cylinder Stop watch. Linear Measuring scale.

Procedure:
1) 2) 3) 4) Produce weld bead-on plate at 3-5 different current setting for DCEP polarity. Record the mean voltage (V) and current (I) for each setting. Cut transverse section on each weld sample. Measure bead width (w), penetration (p) and reinforcement height (h).

Observation:
S. No. Average Average Voltage, Current, V A Time taken for single pass, s 9.2 9.3 8.5 10.1 Penetration, p (mm) 0.528 1 2 3 4 180 175 171 152 28.1 26.3 25.5 22.4 0.764 0.373 0.562 0.877 0.666 0.769 0.876 Bead Width, w (mm) 7.643 6.789 8.654 7.214 6.987 6.002 5.024 6.102 Avg Reinforcement Height, (mm) 1.76 2.548 1.245 1.876 2.924 2.221 2.564 2.923 0.7715 0.8225 6.495 5.563 2.572 2.7435 0.4675 7.934 1.56 0.646 7.22 2.154 Avg p (mm) w (mm) Avg h (mm)

Calculations and Result:

Data used: Cp=0.38(for copper) Electrode feed rate = 5 m/min Sr No 1 2 3 4 EIN (W) 2781.9 2531.37 2398.27 3404.8 m1(g/s) 1.399 1.009 1.418 1.095 m2 (g/s) 0.262 0.262 0.262 0.262 EUTILIZED Efficiency (W) 1517.85 984.019 1383.4 1067.82 54.561 38.872 57.683 31.362

Conclusion:
1. The efficiency depends upon the motion of the torch and electrode feed rate. 2. Electrode feed should be consistent while moving the torch smoothly. 3. The efficiency also depends upon the gap between work-piece and the torch, and also on human skills doing the job.