Experimental Study And Optimization Of Welding Parameters Of V Groove Joints On Aisi4130 Material Using Shielded Arc Welding

Abstract

Shielded metal arc welding (SMAW) is widely employed in heavy industries to join materials; however, it frequently ignores delicate connections that impair weld quality. AISI 4130 chromium-molybdenum alloy steel has unique weldability challenges, demanding a rigorous approach to welding parameter optimization with modern technologies. The objective of this study optimizes shielded arc welding parameters for V-groove joints in AISI 4130 alloy steel to maximize ultimate tensile strength (UTS), hardness, bending strength, and compressive strength. It also experimentally validates the predictive capability of Response Surface Methodology (RSM). The study result discovered that welding current is the most critical component in producing robust mechanical characteristics at RSM optimized parameter values of 200 A, 2.5 mm, and 70°. The study also discovered complicated non-linear interactions, indicating that synergistic parameter combinations are the source of optimum features. Experimental validation showed the mechanical properties boosted capacity, with a 2% average improvement. RSM-optimized settings (200 A, 2.5 mm, 70°) resulted in strong mechanical characteristics (UTS: 1110 MPa, hardness: 112 HRB, compressive strength: 860 MPa, and bending strength: 840 MPa). The models' dependability is demonstrated by their low prediction errors (4.18% for RSM). In this work, the selection of SMAW parameters is moved from empirical approaches to a data-driven science. RSM integration creates a reliable and repeatable foundation for precision manufacturing. With this method, high-integrity AISI 4130 welds with customized, exceptional mechanical qualities that are appropriate for crucial structural applications can be produced. For AISI 4130 steel, welded V-groove joint integrity and durability in critical applications hinge on key mechanical properties—ultimate tensile strength, hardness, bending/compressive strength, and impact toughness—that guide RSM-optimized shielded metal arc welding parameters for ASTM-compliant, base metal-exceeding performance.