Experimental Investigation And Optimization Of Welding Process Parameters Of Mild Steel Plate During Metal Inert Gas Welding

Abstract

Metal Inert Gas Welding (Mig) Is An Arc Welding Process Uses A Consumable Electrode Covered With A Coated Wire To Lay The Weld. This Welding Process Can Be Used For Different Material Types. It Was Often Used For Light To Heavy Duty Work Involving Iron And Steel, Like Carbon Steel, Cast Iron And Nickel Alloys. This Study, Has Focused On The Effect Of Mig Welding Quality On Tensile Strength And Hardness Has Investigated A Design Of Experiment Has Low Carbon Steel In The Case Of Ethiopia. High Dependability All Position Capability, The Convenience Of Use Of Cheap Cost And High Productivity Are The Main Benefit Of Employing Metal Inert Gas (Mig) For Surface Among All Methods. This Process Is Extensively Used Procedure For Joining Mild Steel, Alloy Steel And Other Metal. The Parameters Like Welding Current, Welding Voltage, Welding Speed And Welding Angle) Affected Mechanical Properties (Tensile And Hardness Test, Bead Geometry, And Microstructural Properties Of Mild Steel Aisi4130welded Metal Using Taguchi Methods. For Each Case Sixteen Welded Test Sample Were Generated Using Taguchi Orthogonal Array Design And Variety Welding Condition. TheseAisi4130 Materials Were Commonly Used In Industrial Application Such As Roller Sprocket, Gear Shaft, Machine Component And General Engineering Products. As A Result, The Above Mig Welding Parameters For Weld Quality Of Welded Were Optimized In The Study Using Taguchi Based Desirability Function Analysis And Other Tools Like Analysis Of Variance(Anova)Technique By Minitab 17 Software. Those Test Was Used To Evaluate The Welding Defect Of Both Welded Sample And The Same Specimen Are Defect Free For Both Welded Samples Employing Aisi 4130 Respectively, The Microstructure Of Weld Metal Produced Consists Of A Skeleton E-Ferrite In An Austenite Matrix From The Result Of Optical Microscopy. The Tensile Strength Experimental Results Revealed That Welding Current, Followed By Welding Speed, Was A Highly Significant Parameter For Tensile Strength. Weld Metals Had Higher Hardness Than Base Metals, This Was Supported By The Fact That The Vickers??S Hardness Tests In Both Cases Had Hardness Greater Than A Base For Fusion Zone And Heat Affect Zone Respectively And That No Crack Was Observed In The Weld Metal. Vernier Calipers Can Be Used To Measure The Dimensions Of The Beads. The Quality Of The Welded Junction Is Determined By The Bead Dimensions. With All Combination Of Welding Process Parameters, The Butt Joint Was Selected. Based On Conducted Experiment The Most Significant Control Parameter Was Welding Current With Maximum Contribution Of 44% Whereas Welding Speed Was The Second Parameter With35% Contribution. At Optimized Welding Parameters; The Maximum Tensile Strength Was 761mpa. The Maximum Optimal Hardness Value Of Welded Joint Was 409hv And Weld Beads Joint Was 7.1mm From Desirability Function Analysis Result. As Conducted By Liquid Penetrant Test; The Welding Defects (Porosity, Under Cut, Lack Of Penetration And Others) Were Observed On Sample Number 1 And 7 Whereas Samples Numbers Are Relatively Defect Free Which Was Welded With Optimum Welding Parameters. Percentage Of Tensile Improvement Of Welded Metals Was 63% With A Parametric Setting Of (A1b4c2d3) And Percentage Of Hardness Improvement 33.7% Confirmation Test Results In Agreement With The Predictive Optimum Setting Result This Was In Agreement With Predictive Optimum Setting Value.