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Article in Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture · June 2014
DOI: 10.1177/0954405414537245
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3 authors, including:
Balasubramanian K R M. Vasudevan
National Institute of Technology Tiruchirappalli Indira Gandhi Centre for Atomic Research
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Numerical Simulation of Pulsed Nd-YAG Laser butt welding of AISI 304L Stainless Steel Sheet and Experimental Validation View project
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Original Article
Abstract
In the present work, optimum A-TIG welding process parameters have been determined using the design of experiments
approach to achieve the desired depth of penetration (DOP) during welding of duplex stainless steel (DSS) alloy 2205.
The design matrix for welding experiments was generated using the central composite design of response surface
methodology. Bead-on-plate welds were made on 10 mm thick DSS alloy 2205 plates to generate data and to study
the influence of process parameters on DOP. ANOVA analysis was carried out to determine the significance of the
process parameters. Current was found to be a significant parameter influencing DOP. A second-order response surface
model was developed to predict the response for the set of given input process parameters. Then, numerical and
graphical optimization was performed to obtain the maximum DOP using desirability approach. Validation of the model
showed good agreement between the predicted and actual values of DOP.
Keywords
A-Tungsten inert gas welding, response surface methodology, optimization, process parameters, duplex stainless steel,
desired depth of penetration, bead width, desirability approach
Introduction
technique involves the use of activating flux or acti-
Duplex stainless steel (DSS) alloy 2205 is a class of vating tungsten inert gas (A-TIG) welding which
stainless steel having two phase microstructure con- offers the potential to overcome the limitations of
sisting of approximately equal amounts of d-ferrite the conventional TIG process.3–6 The design of
and -austenite. This equal amount of microstructure experiments (DOE) is a statistical technique, which
offers favorable mechanical properties and corrosion is used for designing the experiments within a
resistance. The two phase microstructure ensures restricted number of trials and to optimize the process
higher resistance to pitting and stress corrosion crack- parameters to attain the required response.7–9
ing when compared to common stainless steels. Owing Chern et al.10 have studied the characteristics of
to its superior mechanical and corrosion properties, the DSS alloy 2205 using A-TIG welding process.
DSS is used as structural material in different indus- They found that the A-TIG welding process increased
trial sectors like chemical, petrochemical, nuclear, fer- the joint penetration and weld depth-to-width ratio
tilizer, food processing, offshore construction, power and also reduced the angular distortion. They
generation, pulp and paper, desalination, and oil reported that by physically constricting the plasma
and gas.1,2 column and reducing the anode root, the weld depth
Tungsten inert gas (TIG) welding is one of the increased and bead width decreased. Tseng and Hsu11
most important technologies for welding thin, as
well as thick materials of DSS in various manufactur- 1
Department of Mechanical Engineering, National Institute of
ing industries, as it produces clean, precise, and high- Technology, Tamil Nadu, India
2
quality welds. However, the major disadvantage of Materials Technology Division, Metallurgy and Materials Group, Indira
the TIG process is the limitation on the thickness of Gandhi Centre for Atomic Research, Tamil Nadu, India
the material that can be welded in a single pass (lim-
Corresponding author:
ited to 3 mm). Therefore, it is essential to enhance the KR Balasubramanian, Department of Mechanical Engineering, National
depth of penetration (DOP) achievable in single pass Institute of Technology, Tiruchirappalli 620 015, Tamil Nadu, India.
TIG welding and also the productivity. The improved Email: krbala@nitt.edu
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have performed the A-TIG welding experiments on which a response of significance is influenced by a
6 mm thick 316L stainless steel plates to investigate number of process parameters and the objective is
the effect of MnO2, TiO2, MoO3, SiO2, and Al2O3 to optimize the response.7 The major objective of
oxide fluxes on the weld morphology, angular distor- RSM is to estimate the input process parameters at
tion, d-ferrite content and hardness. They reported which the responses achieve their optimum. RSM is
that the centripetal Marangoni convection and con- the most important technique that can give significant
stricted arc plasma increased the DOP of A-TIG information about the interaction effects between the
welds of 316L stainless steel plates. Benyounis process parameters. It also gives the required infor-
et al.12 have applied RSM to optimize the laser mation for design, process optimization and multiple
welded butt joint of medium carbon steel parameters responses for various manufacturing processes.19–21
using desirability approach. Giridharan and In this research work, RSM was used to generate
Murugan13 have optimized the parameters of pulsed the mathematical relation between the output
gas tungsten arc welding process using RSM. Zhang response ‘‘Y’’ and the different process parameters
and Liu14 have established a mathematical relation- of the A-TIG welding of DSS alloy 2205. The depend-
ship between tensile strength and welding parameters ent variable Y is considered as a function of independ-
to determine the tensile strength of underwater fric- ently controllable welding process parameters such as
tion stir welding process using RSM. Razal Rose welding current, torch speed, and arc gap and can be
et al.15 have optimized the pulsed current TIG weld- expressed as
ing process parameters to predict the maximum ten-
sile strength using RSM. Juang and Tarng16 have Y ¼ f ðx1 , x2 , . . . , xk Þ ð1Þ
optimized the weld pool geometry of TIG welding
of stainless steel using modified Taguchi method. where xk is the variable factor. In the common appli-
Korra et al.17 have performed A-TIG welding cations of RSM to optimize the response ‘‘Y’’, a
response optimization using the desirability approach regression model is developed. The second-order poly-
for obtaining the maximum DOP of super duplex nomial equation can be given as
stainless steel alloy 2507. Huang18 studied the effect
of activating flux and parameters of the weld bead X
k X
k k1 X
X k
profile of gas metal arc welding using Taguchi Y ¼ b0 þ bi xi þ bii x2i þ bij xi xj ð2Þ
i¼1 i¼1 i¼1 j¼2
method.
Optimization of parameters to achieve the desired
weld bead during A-TIG welding is important and where b0 is the average of responses and bi, bii, and bij
there is a lack of literature related to optimization are the coefficients which depend on respective main
studies. In this research work, the optimization of and interaction effects of the parameters.
A-TIG welding of DSS alloy was carried out using The number of experiments conducted in the pre-
RSM. The analysis was carried out to study the influ- sent case was 34 and the number of welding process
ence of A-TIG welding parameters on the DOP in parameters considered was three. The design matrix
10 mm thick DSS alloy plates and to predict the opti- was developed as per rotatable central composite
mum welding conditions using the desirability design of RSM. Three factors were varied at five
approach for achieving maximum DOP in single levels, resulting in two replicates of factorial points,
pass welding. The parameters identified will be very two replicates of axial (star) points, and six center
useful for the manufacturing industries. points.
Elements C Si Mn S P Cr Ni
Korra et al. 3
cleaned with silicon carbide paper to remove dirt and locations from the beginning of the weld. The samples
cleaned with acetone prior to the experimental work. were polished with silicon carbide emery papers and
The multi-component specific activated flux devel- etched using an electrolytic etching with 25% KOH,
oped at IGCAR, India was used in the present 75% distilled water at 5 V for 60 to 90 s to view the
study.6 The flux in the powder form was kept in the macrostructure of the weld samples. The DOP was
oven for about an hour to remove moisture from the measured using a microscope, which has the attach-
flux and made into a paste by adding acetone. ment of the digital readout counter, and was used to
The flux paste was applied on the surface of the measure both x- and y-axis. The data (DOP) were
DSS plates with the help of a paint brush as a thin collected at two locations for each trial parameter
coating prior to the welding. Figure 1 shows a sche- combination and the average value was taken to min-
matic diagram of flux preparation and coating on the imize the measurement and human error. The input
typical plate. A-TIG bead-on-plate welds were made process parameters and measured response were fed
on DSS plates in a single pass. A 2% thoriated tung- into the design expert v7 software for statistical ana-
sten electrode of diameter 3.2 mm with 60 tip angle lysis. Figure 2 shows the top surface of typical bead
and argon as shielding gas with a flow rate of on plate welds. Figure 3 shows the cross section of
10 L/min was used. The experiments were performed typical weld bead profiles. Table 2 shows process con-
as per the design matrix to study the effect of A-TIG trol variables in coded and actual values. The ranges
welding process parameters on the DOP. In order to and levels of control variables are fixed based on the
measure the DOP, the 34 welded samples were cross specification of welding machine, thickness of the
sectioned in the transverse direction of welding at two material, preliminary experimental trials, and
Figure 1. Schematic diagram of flux preparation and coating on the DSS alloy 2205.
Levels
Current Torch speed Arc gap DOP Current Torch speed Arc gap DOP
Std Run (A) (mm/min) (mm) (mm) Std Run (A) (mm/min) (mm) (mm)
Korra et al. 5
Source Sum of squares df Mean square F-Value p-Value Prob > F Contribution percentage
Figure 5. Interaction effect of current and torch speed on the depth of penetration: (a) the response surface and (b) the contour
plot.
Figure 6. Interaction effect of current and arc gap on the depth of penetration: (a) the response surface and (b) the contour plot.
Korra et al. 7
Figure 7. Interaction effect of torch speed and arc gap on the depth of penetration: (a) the response surface and (b) the contour
plot.
Table 6. Continued
Torch
Current speed Arc gap Actual Predicted RMS
S. No. (A) (mm/min) (mm) value value error
Korra et al. 9
Marangoni convection which occurs due to of the flux on the overlay plot in Figure 8 shows the regions that
disintegration.4,6,10 The weld shape variation in A- meet the proposed criteria.
TIG welding is caused by the surface active elements
like oxygen and sulphur.10 The heat input to the Validation of the optimum solutions identified
material is increased due to flux which helps in
increased OP.
by the model
The interaction effect of current and arc gap on The validation experiments were carried out for the
DOP is shown in Figure 6. The parameter torch optimal solutions identified in the model for achieving
speed is kept constant at 90 mm/min. At the lower the maximum DOP. Randomly three sets of process
arc gap, the arc is constricted leading to high arc parameters were chosen from the optimal solutions
energy density in the center of the arc due to higher list for the validation experiments. From Table 7 it
movement of the free electrons. This results in better is observed that to obtain higher penetration, the cur-
focus of the arc leading to more DOP. Tseng and rent must be higher and the torch speed must be
Hsu.11 have also reported that the constricted arc lower. Table 7 shows the actual values of the DOP;
plasma and centripetal Marangoni convection were model predicted values and the calculated root mean
the reason for increased weld bead penetration. At squared error (RMSE) for the validation set. The
the lower arc gap and higher current, the amount of RMSE value shows the minimum difference between
heat input to the material is increased, which leads to the actual and predicted values, which shows the
an increased DOP. As the current increases from 100 model is fairly accurate. The RMSE value was pre-
to 300 A for a constant arc gap (say 1 mm) the DOP dicted using the following equation
increases. Similarly for a constant current (say 100 A),
sffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
the increase in the arc gap from 1 to 5 mm
X Ypred Yref 2
leads to decrease in DOP due to decrease in the RMSE ¼ ð6Þ
energy density. N
The interaction effect of torch speed and arc gap
on DOP is shown in Figure 7. The parameter current where Ypred is the model predicted value, Yref is the
is kept constant at 200 A. It is observed that at lower laboratory measured value, and N is the number of
torch speed and lower arc gap, the amount of heat samples. The RMS error obtained was 1.21 for the
input to the material is more, which leads to the validation experiments.
increased DOP. As the torch speed increases from
60 to 120 mm/ min for a constant arc gap (say
1 mm), the DOP decreases. Similarly, if the arc gap
Conclusions
increases from 1 to 5 mm for constant torch speed 1. RSM is found to be an accurate method for opti-
(say 60 mm/min) the DOP also decreases. Similar mizing the A-TIG welding process parameters in
results were obtained by Korra et al.17 during order to obtain the desired DOP in duplex stain-
A-TIG welding of super duplex stainless steel less steel alloy 2205. The second-order quadratic
alloy 2507. model is successfully used to predict the DOP
during A-TIG welding of DSS plates.
2. The welding current has more effect on the DOP
Optimization using desirability approach of A-TIG welding of DSS plates compared to that
Optimization of process parameters in design expert of the other process parameters.
v7 software finds a combination of factor levels, 3. The graphical optimization gives the overlay plots,
which satisfy essential optimization criteria on the which results in quick visual inspection of the
response. Numerical and graphical optimization pro- region of feasible response values in the parameter
cess was performed by selecting the required goals for space to select the optimum process parameters
all process parameters and response. Numerical opti- for A-TIG welding of DSS alloy 2205.
mization technique contains combining the goals into
an overall desirability function. The numerical opti-
Funding
mization aspect in the design-expert software finds
one point or more in the factor domain that would This research received no specific grant from any
funding agency in the public, commercial, or not-for-profit
maximize this objective function. In graphical opti-
sectors.
mization with response, the design-expert software
defines regions where requirements meet the proposed
criteria, and overlaying critical response contours can Acknowledgement
be defined on contour plot. Table 5 shows the opti- The authors would like to sincerely thank the Director,
mization criteria for generating the optimal solutions Metallurgy and Materials Group, Indira Gandhi Centre
during A-TIG welding of DSS. Table 6 shows optimal for Atomic Research (IGCAR), Kalpakam for extending
solutions which were generated using DOE software the experimental facility and the National Institute of
based on optimization criteria. The bright yellow area Technology, Trichy for analytical support.
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