International Journal of Advanced Research in Technology, Engineering and Science (A Bimonthly Open Access
Online Journal) Volume2, Issue2, March‐April, 2015. ISSN: 2349‐7173(Online).
Effect of Welding Current, Arc Voltage and Gas
Flow Rate on Depth of Penetration during MIG
Welding of AA2014 Plate
R.Sakthivel1*, P.Venkadeshwaran1, R.Sridevi1, R.Ahamed Meeran1, K.Chandrasekaran1 .
____________________________________________
Abstract:  welds. T6 - Solution heat treated and artificially aged [3].
In the present work, bead-on -plate welds were carried
out on AA2014 Aluminum Alloy plate using Metal Inert
Gas Welding (MIG) process. In this present investigation
ER4043 solid wire having 1.2 mm diameter was used as
an electrode with direct current electrode positive
polarity. An argon gas was employed for shielding
purposes. The fusion zone is generally characterized by a
few geometrical features namely bead width,
reinforcement and depth of penetration. The shape of the
fusion zone depends upon a number of parameters such
as gas flow rate, voltage and welding current. Taguchi
Technique is applied to plan the experiments. The weld
bead geometry plays an important role in determining the
mechanical properties of a weld joint. Therefore, it is
important to set up proper welding parameters to produce
a good weld bead.
______________________________________________
Keywords: MIG welding, AA2014 plate, Taguchi
orthogonal array, bead geometry.
___________________________________________
1. Introduction:
Metal Inert Gas welding (MIG) process is an important
component in many industrial operations. The GMAW
parameters are the most important factors affecting the
quality, productivity and cost of welding [1].GMAW
process a continuous and consumable wire electrode is
used. A shielding gas generally argon or sometimes
mixture of argon and carbon dioxide are blown through a
welding gun to the weld zone. Electrode melts due to the
heat and molten filler metal falls on the heated joint [2].
Machinability of aluminum alloy 2014 is very good.
Typical applications of aluminum alloy 2014 are high
strength components especially for use in the aerospace
and marine industries .The aluminum alloys and copper are
difficult to weld because of the high thermal conductivity,
high thermal expansion and a tendency to give porous
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During a manual welding operation, the welder has to have
control over the welding variables, which affect the weld
penetration, bead geometry and the overall weld quality. A
proper selection of welding variables will increase the
chances of producing welds of a satisfactory quality
[4].The weld and bead geometry plays an important role in
determining the mechanical properties of the weld [5].
Hence the input welding process variables which influence
the bead geometry must therefore be properly selected to
obtain an acceptable high quality joint [6]. They conducted
experiments based on five process parameters to obtain
bead geometry using GMAW process. From the study it
was inferred that welding voltage, arc current, welding
speed and welding angle have large significant effects on
bead geometry developed an approach to predict and
optimize weld bead geometry in GMAW [7].The bead
geometry and penetration affect the weldments
characteristics and are dependent on a number of welding
variables. In the present investigation an attempt was made
to study some of the weldments characteristics such as
bead height, bead width and depth of penetration, as
affected by welding parameters like arc-voltage, travel
speed, wire feed rate and gas flow rate. And also its effect
of the microstructural changes in the weld zone and
hardness variation across the bead on the MIG welded
AA2014 plate [8]. Dr. Taguchi of Nippon Telephones and
Telegraph Company, Japan has established a method based
on "orthogonal array" experiments which gives much
reduced "variance" for the experiment with "optimum
settings" of control variables. Thus the marriage of Design
of Experiments with optimization of control parameters to
find best results is attained in the Taguchi Method. Taguchi
technique is used to increases the output and reduced the
cost of the products. The Taguchi Design is based on
orthogonal array. Taguchi design recognizes the control
factors to minimize the effect of Noise factor. Orthogonal
array helps to reduced the time and cost of the experiment.
 
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The Signal-to-Noise (S/N) Ratio
o which are log
g function of has been shown in F Figure 1. A schematic
s illusstration of
uired output, which
requ w is the objective funnction to be bead peenetration in welding
w applicaations has beenn shown in
optim
mized [9]. A Schematic Diagram of GM MAW System Figure 2.

 
Fig.1. A Schematic Diagram
D of GMMAW System
currentt the welding voltage was varied as V11=25V &
voltagee the current wwas I1=75A & I2=100A
I and aat constant
V2=30V.Tensile streength is morre when currrent is at
100A.T Toughness propperty is foundd to be good att V1=25V
and othher are nearer tto it. Hardness is more at I1= =75A & at
V2=30V.Latfe,et al.[11] MIG weldding is a well established
way off joining varioous aluminum m alloys, althouugh some
alloys, notably thosee in the 2XXX X and 7XXX series,s are
difficullt to fusion weeld. MIG weldding employs an a electric
arc, strruck between the filler rod and the material being
weldedd, to generatee localized heeat.Due to thee reactive
nature of aluminum, the arc is shrrouded by an inert gas,
generallly argon, prootecting the baase metal from m contact
Fig.2.
F A Schem matic diagram of weld bead geometry
g
with oxygen,
o nitrogeen or hydrogeen. Rakesh Shharma, et
al.[12] After the wellding process, the weld beadd samples
2. Literature
L Revviews
are cutt from each weeld bead at 15 mm intervalss, with the
Literrature shows that
t work has been exploredd on various
first saample being loocated at 15 mm m behind thhe trailing
aspeects of modelin ng, simulationn and process optimization
edge ofo the crater eend to eliminaate the end efffects. The
in MIG
M welding. In I this study, detailed analyysis has been
transveerse faces of thhe specimens were
w further preepared for
madde to establlish relationsships betweeen welding
study ofo weld bead geometry. Sppecimens weree polished
paraameters and weld w bead geometry and weld w quality
with various grades of emery pappers, starting w with 150,
lead
ding to an optiimal process. P K Palani, et e al.[9] The
180, 32 20, 400, 800, 1200 and SIA A Signor B 16000. Water
DOE E using Taguchhi approach caan significantly y reduce time
was used as coolant. The bead geoometry was meeasured on
requuired for expperimental invvestigations 6-8. 6 In this
the etcched sample by optical microscopy.
m T
The bead
inveestigation, in thhe first stage, Taguchi's
T orthoogonal arrays
dimenssions of the weeldment were measured
m from
m the base
weree used to conduct
c the experiments
e t find the
to
metal. Sathiya, et al.[[13]Summariziing, it can be stated
s that
conttributions of eaach factor and to optimize th he parameter
the beaad geometry and a penetratioon affect the weldment
settings.
charactteristics and arre dependent on o a number of o welding
Oladdele, et al.[10]] Worked on Wrought
W alum minum alloy
variables. In the preseent investigatioon an attempt w was made
for investigation using MIG welding w .The current and
to study y some of the weldment charracteristics succh as bead
voltaage is used as parameters
p currrent and voltaage on tensile
height, bead width annd depth of pen netration, as afffected by
strenngth, Since inn arc welding is directly rellated voltage
welding g parameters liike arc-voltagee, travel speed, wire feed
and current, the tw wo conditions are applied i.ee. at constant
rate annd gas flow rate. And also a its effecct of the

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micrrostructural chhanges in the weld zone and a hardness been performed
p to get the approopriate parameeter range
variaation across th
he beads on thee GMA weldedd AISI 904 L where welding
w could be possible annd no observabble defects
(UNNS N08904) supper austenitic stainless
s steel. like undercutting
u aand porosity occurred. The T bead
3.E
Exprimental Details
D geomettry was measuured on the ettched sample by b optical
The experiments were
w carried onn AA2014 alum minum alloy microsccopy. The beaad dimensions of the weldm ments were
platees of size 1500mm × 50mm × 6mm. GMA AW welding measurred from the bbase metal. The chemical composition
was used in experriments as it cooncentrates thee heat in the of AAA2014 and thee filler materiaal is given inn table 1.
weldding area. ER 4043
4 electrodees of diameter 1.2
1 mm were Factorss affecting the GMAW weld ding and their levels are
taken as electrodee for this experiment. Beforee performing given in table 2 annd the experim mental layout using L9
the actual
a experimment a numberr of trial experriments have orthogoonal array are given
g in table 3.
3
Material
M Cu M
Mg Mn Fe Si Zn Ti C
Cr A
Al

A
AA2014 4.2 0
0.6 0.2 0.5 0.7 0.2 00.15 0.1 REM
M 95.17
Filler wire Cu M
Mg Mn Fe Si Zn Ti Br A
Al
ER4043 0.30 0..05 0.05 0.8 4.5 0.10 00.20 0.00033 RE
EM

Table 1. Chhemical compoosition of base metal and filleer wire used

varriables U
Unit Leveel-1 Level-22 Level-3
4. Ressult and Discuussion
Cu
urrent A
Amp 180
0 200 220 The macrograph
m of the welded sample
s is preesented in
Figure 3, It is observed that the surrface of the weelded plate
Voltage v
volt 244 26 28 n and good. Thhe weld zone, iff free from cracks for all
is clean
Gaas flow Litt/min 177 19 21 the exp perimental runns is considerred for bead geometry
rate measurrement. The exxperimental reesults for the weldw bead
geomettry are presennted in Table 4. Heat input plays an
Table
T 2. Levell of GMAW welding
w processs variable
importaant factor for determining the bead geoometry. In
generall, due to the hhigh amount of o heat input i.e.,
i larger
Samp
ple no Current
C Voltage
V Gas flow amountt of heat depoosited on the surface leads to higher
(A) (V) rate (L/min)) penetraation.

1 180 24 17

2 180 26 19

3 180 28 21

4 200 24 19

5 200 26 21

6 200 28 17

7 220 24 21

8 220 26 17

9 220 28 19  
Fig.3. Macro
ograph of the welded
w samplle
Table 3.
3 L 9 orthogonnal array desiggn 

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Sample no Current Voltage Gas flow Depth of Bead width Bead height
(A) (V) rate (L/min) penetration (mm) (mm)
(mm)

1 180 24 17 7.28 11.99 1.92

2 180 26 19 7.33 11.9 2.05

3 180 28 21 7.38 12.0 2.90

4 200 24 19 8.20 12.4 3.30

5 200 26 21 7.38 12.0 2.78

6 200 28 17 8.10 12.24 3.26

7 220 24 21 7.22 12.23 1.58

8 220 26 17 7.96 14.29 3.24

9 220 28 19 7.16 15.20 3.02

Table 4. Experimentally measured values

4.1 Level average response analysis using average value

The level average analysis is based on combining and Table 5. Average effect of welding current on bead
averaging the response associated with each level for each dimensions
factor. From the average data of each of the experiments
where in one level of each factor occurs, the optimum
value of factors is determined. For the analysis of weld Welding Depth of Bead Bead
quality generated by MIG welding process, penetration, Voltage penetration width height
bead width and bead height of the weld were considered. (V) (mm) (mm) (mm)
From the level average response analysis using the average
values of each trial run, the optimum conditions for each of 24 7.57 12.20 2.27
the factors Voltage (V), Welding Current (I) and Gas Flow
Rate (G) can be determined. Average effect of current on 26 7.56 12.73 2.69
bead dimensions are given in Table 5, Average effect of
welding voltage on bead dimensions 6 and Average effect 28 7.55 13.14 3.06
of gas flow rate on bead dimensions 7.
Welding Depth of Bead Bead Table 6. Average effect of voltage on bead dimensions
Current penetration width height
(A) (mm) (mm) (mm) Welding Gas Depth of Bead Bead
flow penetration width height
180 7.33 11.96 2.29
rate (L/min) (mm) (mm) (mm)
200 7.89 12.22 3.12
17 7.78 12.84 2.80
220 7.45 14 2.62

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19
1 7.56 13.17 2.79 voltagee may cause poorosity and oveerlapping at thee edges of
the weeld bead. Effecct of voltage on
o bead dimennsions are
21
2 7.33 12.08 2.42 shown in figure 5.

Table 7. Aveerage effect of gas flow rate on o bead

dimensioons
4.1
1.1 Effect of cuurrent on bead d dimensions
The value of weldding current useed in MIG hass the greatest
effecct on the deposition rate, the weld bead sizze, shape and
the penetration.
p th
he current will increase the depth
d and the
widtth of the weld penetration
p andd the size of thhe weld bead.
An excessively
e low welding currrent for a giv ven electrode
size produces a pooor penetration and the pileupp of the weld
metaal on the surfacce of the base metal transfer by the arc is
sluggish, the beadd is rough andd reinforcemennt high If the
curreent is too highh, the size of the
t weld bead is large and
the excessive
e deepp penetration that
t wastes thee filler metal
causses burn-through and underccut. Too highh or too low
weldding current also affects thee mechanical properties
p of   
the weld
w metal andd the tensile strrength. Effect of o current on Fig.5. Effect of voltage on bead
b dimensionns
beadd dimensions are
a shown in figgure 4.
4.1.3 Effect of gas flow rate on bead diimensions
Argon, helium and argon-helium m mixtures aree used in
many applications ffor welding non-ferrous
n m
metals and
alloys. These inert gaas mixtures proovide lower meelting rate,
smallerr penetration and narrow bead b contour. Argon is
cheaper than helium and helium-arggon mixtures aand it also
produces less spatterr. Unlike argon, helium impproves the
weld bead
b penetratioon profile (highher melting raate, deeper
penetraation and convvex surface pro ofile). But, wheen helium
is usedd, welding volttage rises for the
t same arc length and
the connsumption of shhielding gas inncreases more than
t when
argon isi used. Effectt of gas flow rate
r on bead diimensions
are shoown in figure 6.

Fig.4. Effeect of current on

o bead dimenssions

1.2 Effect of voltage

4.1 v on bead d dimensions
In MIG
M the arc voltage has a decided effeect upon the
peneetration, the bead
b reinforcemment and bead d width. By
increeasing the arcc voltage the weld
w bead beccomes flatter
and wider, the pennetration increaases until an opptimum value
of the
t voltage iss reached, at which time it i begins to
decrrease. Low voltage
v producces narrower beads with Fiig.6. Effect of gas flow rate on
o bead dimenssions
greaater convexity (high crown n), but an exxcessive low

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4.1
1.4 Macrograp ph of the Bead d geometry Profiles
The smooth bead d profile microo graphs are presented
p in
ure 2. The fusiion line zone is
Figu i clearly visibble in all the
micrro graphs. In Figure 7 (sam mple 1 to 9) thet depth of
  
peneetration is partiially full in all the micro grapphs.

  
  

  
Fiig.7. Macrograaph of the Bead d geometry Proofiles 
   5. Conclusioons
The preesent focus onn MIG welding g parameter onn AA2014
under different weldding condition n the followinng on the
me of this reseaarch.
outcom
1.The effect of wellding current increases the depth of
penetraation is constannt, the bead wiidth and bead height
h are
   increassed.
2.The effect of arrc voltage in ncreases the depth of
penetraation is constannt, the bead wiidth and bead height
h are
increassed.
3.The effect of gass flow rate increases
i the depth of
penetraation, the bead width and beaad height are deecreased.

   Referencess
[1] S. V.. Sapakal, M. T. Telsang,
T 2012. “Paarametic optimizaation of MIG
welding using Taguchi dessign method ”,International Journal oof Advanced
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[2] Kulekkci, M. 2005 Metaallurgy, vol .44, Noo.3.
[3] Alumminum welding guiide, www.harriscaal .com
[4] Ramanaiah, N. 2004 IInternational Sym mposium of Researrch Students
on Materials Science and Engineering Deccember 20-22, Chhennai, India
Departmment of Metallurgiccal and Materials Engineering, Inddian Institute
   of Technnology Madras.
[5], Y.S. and W.H.,Yang, 1998. “Optimizattion of weld bead geometry in
GTAW by b Taguchi method”, Int J Adv Mannuf Technol, Vol. 14, pp.549 –
554.
[6] Mostafa, N.B and M.N.,
M Khajavi, 200 06 “Optimization of welding
parameteers for weld penettration in FCAW””, Journal of Achiievements in
Materialss and Manufacturiing Engineering.V Vol. 16, pp.132 – 1338.
[7] Farhhad Kolahan and Mehdi Heidari, 2010. “A new approach a for
   predictin
ng and optimizing weld bead geomeetry in GMAW”, International
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 International Journal of Advanced Research in Technology, Engineering and Science (A Bimonthly Open Access 
Online Journal) Volume2, Issue2, March‐April, 2015. ISSN: 2349‐7173(Online). 
 
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Biography

Mr.R.Sakthivel,(B.E)., Department of
Mechanical engineering., Nadar Saraswathi College of
Engineering and Technology., Theni. He had published one
paper in refereed International Journal and Conference.
 Dr. K.Chandrasekaran, B.E., M.E., PhD, MISTE, obtained
his Bachelor Degree in Mechanical Engineering and
Master Degree in Manufacturing Engineering from Anna
University Chennai and Anna University of Technology
Tiruchirappalli. He completed his PhD in the area of
Manufacturing Engineering and Optimization from Anna
University, Chennai. Now he is working as an Assistant
Professor in Nadar Saraswathi College of Engineering
College, Theni. He had published number of papers in
refereed International Journals and Conferences.

_______________________________________________

Authors Address:
Mr.P.Venkadeshwaran,(B.E)., Department of Mechanical
engineering., Nadar Saraswathi College of Engineering and 1
Department of Mechanical Engineering, Nadar
Technology., Theni. He had published one paper in Saraswathi College of Engineering and Technology,
refereed International Journal and Conference. Theni, Tamilnadu, India.
*
Corresponding Author Email ID:
sakthi.rajen71@gmail.com 
___________________________________________

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