Optimization of Process Parameters of GMAW for Penetration, Toughness and Tensile Strength by using Taguchi Method

Abstract

Aluminum and its alloys are having variety of applications in Aircraft, food processing etc. Moreover; the use of Aluminum and its alloys are increasing day by day due to its specific properties, like light weight, high strength, and excellent corrosion resistance. However; the present study is planned to analyze and optimize the aluminum weld joint characteristics like tensile strength, penetration and toughness by using Gas Metal arc welding (GMAW) welding. Furthermore; welding current, voltage and welding speed are selected as independent parameters for conducting experimental runs. Total nine experiments are performed for welding of aluminum 6061 tempered alloy sample using semi-automatic GMAW welding model PRO-4200 current range 10 A-420 A and voltage range 10 V-41 V. The welding responses; such as tensile strength, penetration and toughness of welded samples were measured for all nine samples Statistical analysis of variance (ANOVA) test is conducted to determine the significant process welding parameters on weld joint characteristics response. From; the ANOVA results, it is found that welding parameters are most significant for weld joint strength of aluminum alloy in GMAW welding operation. Taguchi methodology is applied on experimental data to obtain the optimum welding input parameters to maximize the penetration, toughness and ultimate tensile strength. Confirmatory tests are validating the optimized conditions by Taguchi method.