Journal of Materials Processing Technology, 37 (1993) 767 780

767

Elsevier

Effect of submerged arc process variables

on dilution and bead geometry in single wire
surfacing
N. Murugan
Welding Laboratory, Department of Mechanical Engineering, IIT, New Delhi, India

R.S. Parmar
Department of Materials Technology, Brunel University, UK

and
S.K. Sud
IDDC, IIT, New Delhi, India

Industrial S u m m a r y
Weld s u r f a c i n g is the t e c h n i q u e of depositing a layer of m a t e r i a l o n t o the surface of
a c o m p o n e n t to m a k e it more r e s i s t a n t to wear, c o r r o s i o n or h i g h t e m p e r a t u r e t h a n the
p a r e n t m e t a l or substrate. This e n h a n c e s p r o d u c t i o n economies by e n a b l i n g the use of
a cheaper, more easily m a c h i n a b l e p a r e n t m a t e r i a l coated with expensive m e t a l s a n d alloys
for a c h i e v i n g desired properties in specific areas of products. It h a s become more p o p u l a r
t h a n t h e pre-cladding of m a t e r i a l s as it is employed at the final stage of fabrication. Weld
s u r f a c i n g is employed for the f a b r i c a t i o n of new c o m p o n e n t s for use in chemical a n d fertilizer
plants, n u c l e a r power plants, pressure vessels, a g r i c u l t u r a l m a c h i n e s a n d even a i r c r a f t a n d
missile components. Also, it h a s been used widely for m a i n t e n a n c e a n d r e p a i r of r a i l w a y
rolling stock as well as points and j u n c t i o n s , e a r t h m o v i n g a n d a g r i c u l t u r a l m a c h i n e r y ,
large gear wheels, c o n v e y o r shafts, chutes, t u r b i n e c o m p o n e n t s a n d i n n u m e r a b l e o t h e r
components.
T h o u g h weld s u r f a c i n g is carried out by v a r i o u s t e c h n i q u e s , a u t o m a t e d s u b m e r g e d arc
welding is t h e p o p u l a r l y employed t e c h n i q u e due to its h i g h quality and reliability. Also, by
the p r o p e r selection of t h e process control p a r a m e t e r s , single wire s u r f a c i n g becomes one of
the cost effective m e a n s of depositing a corrosion r e s i s t a n t overlay. However, for use of SAW
in its a u t o m a t i c mode, the c o n t r o l p a r a m e t e r s are required to be fed to t h e system a c c o r d i n g
to some m a t h e m a t i c a l f o r m u l a t i o n to achieve the desired end results: the p r e s e n t paper deals
w i t h the d e v e l o p m e n t of such models. M a t h e m a t i c a l models were developed by u s i n g a five
level factorial t e c h n i q u e to predict t h e weld bead geometry for depositing 316L stainless steel

Correspondence to: N. M u r u g a n , Welding L a b o r a t o r y , D e p a r t m e n t of M e c h a n i c a l Engineering, IIT, New Delhi-110016, India.

0924-0136/93/S06.00 ',C 1993 Elsevier Science P u b l i s h e r s B.V. All r i g h t s reserved.

768

N. Murugan et al./ Single wire surfacing

onto structural steel IS 2062. The responses, namely, penetration, reinforcement, width and
dilution as affected by open-circuit voltage, wire feed-rate, welding speed and nozzle-to-plate
distance, have been investigated. The models developed have been checked for their ad~
equacy and significance by using the F-test and the t-test, respectively. The main and
interaction effects of the control factors on dilution and bead geometry have been presented
in graphical form, which is more useful in selecting the process parameters to achieve tile
desired quality of the overlay.

1. I n t r o d u c t i o n

Weld s u r f a c i n g is not o n l y an i n d i s p e n s a b l e process in the r e p a i r and

m a i n t e n a n c e industries, but is also e m p l o y e d i n c r e a s i n g l y in the process and
p o w e r industries. It is applied m a i n l y to i n c r e a s e the life of c o m p o n e n t s
o p e r a t i n g u n d e r c o n d i t i o n s of w e a r and c o r r o s i o n by h a r d - f a c i n g and cladding
a n d to r e d u c e t h e i r cost by r e p e a t e d r e b u i l d i n g [1]. T h o u g h it is c a r r i e d out by
n u m e r o u s welding m e t h o d s s u c h as SMAW, SAW, GTAW, G M A W , FCAW.
ESW, PAW, etc., SAW is the p r e d o m i n a n t m e t h o d due to its h i g h p r o d u c t i v i t y ,
b e t t e r quality, e a s y a p p l i c a b i l i t y and good r e l i a b i l i t y [2].
S u b m e r g e d arc s u r f a c i n g is e m p l o y e d by v a r i o u s t e c h n i q u e s [3,4]: single and
m u l t i p l e wires, single and m u l t i p l e strips, a d d i t i o n a l p o w d e r filler metal,
a d d i t i o n a l hot or cold filler wire or strip; with or w i t h o u t oscillation of the
electrode. T h e single-wire process is employed l a r g e l y for s u r f a c i n g s m a l l e r
a r e a s w h i c h are n o t a c c o m p l i s h e d feasibly by the use of strips, as well as w h e n
h e a t i n p u t to the s u r f a c e is limited [5]. T h e s e processes are employed in
a u t o m a t i c or s e m i - a u t o m a t i c m o d e as it is n o t feasible to c o n t r o l an arc t h a t is
not visible. W i t h the i n c r e a s e of m e c h a n i s a t i o n and r o b o t i c a p p l i c a t i o n s , it is
e s s e n t i a l to h a v e a h i g h degree of p r e c i s i o n in p r e d i c t i n g weld bead s h a p e and
d i m e n s i o n s [6]. Also, successful s u r f a c i n g r e q u i r e s an o p t i m i z a t i o n of the
process p a r a m e t e r s to secure low dilution a n d a c r a c k - f r e e overlay. This
needs a t h o r o u g h u n d e r s t a n d i n g of the process c h a r a c t e r i s t i c s a f f e c t i n g the
t e c h n o l o g i c a l and m e t a l l u r g i c a l c h a r a c t e r i s t i c s of the overlays. Thus, it is
e s s e n t i a l to d e v e l o p m a t h e m a t i c a l models to predict not o n l y the weld bead
d i m e n s i o n s but also the effects of v a r i o u s process p a r a m e t e r s i n f l u e n c i n g
d i l u t i o n (see Fig. 1).
W i t h a view to a c h i e v i n g the a b o v e - m e n t i o n e d aim, s t a t i s t i c a l l y designed
e x p e r i m e n t s b a s e d on the f a c t o r i a l t e c h n i q u e [7] were used to r e d u c e the cost
a n d time, as well as to o b t a i n the r e q u i r e d i n f o r m a t i o n a b o u t the m a i n and the
i n t e r a c t i o n effects on the r e s p o n s e p a r a m e t e r s [8]. A u t o m a t i c s u b m e r g e d arc
s u r f a c i n g was c a r r i e d out by d e p o s i t i n g 316L stainless steel o n t o s t r u c t u r a l
steel IS 2062 p l a t e of 20 m m t h i c k n e s s w i t h ss flux g r a d e I a n d the o b s e r v e d d a t a
w a s used to d e v e l o p the m a t h e m a t i c a l model. T h e c o n t r o l l a b l e process param e t e r s w e r e r e t a i n e d in an o p t i m u m r e g i o n for a c h i e v i n g the a c c e p t a b l e
quality. T h e q u a l i t y of the s u r f a c e d l a y e r depends u p o n the weld dimensions,

N. Murugan et al./Single wire surfacing

769

Width
Reinforcemenf

Penefrotion

~-

t
% Oi~ution = Ap x 100
Ar + A#
Fig. 1. Weld bead geometry.

especially on the dilution, as the latter determines the amount of ferrite

present in the overlay [3,4]. The recommended amount of ferrite to be present
in the overlay to have resistance to microfissuring and hot cracking is of the
order of 5 to 11 FN (ferrite number) [9]. The actual amount present may be
calculated if the composition of both the base metal and the filler metal and the
amount of dilution in the overlay are known [10]. The economies of ss weld
cladding are dependent on achieving the specific chemistry at the practical
deposition rate in a minimum number of layers. Obviously, when the amount of
dilution in the first layer is the least possible, the total number of overlays
required in order to be able to satisfy metallurgical needs is less. By effectively
controlling the dilution, single-wire surfacing by 316L ss onto mild steel has
produced acceptable weld quality [11]. This paper presents mathematical
models developed for predicting the effects of process variable for single-wire
surfacing on dilution and bead geometry from the experimental data obtained,
without delving too deeply into the measurement of ferrite. The experiments
were based on a central composite design matrix of five level full factorial
technique. Regression analysis was used to develop the models and the variance method was used to test their adequacy.
2. Plan of i n v e s t i g a t i o n
The research work was planned to be carried out in the following steps:
(1) identifying the important process control variables;
(2) finding the upper and lower limits of the control variables, viz., open
circuit voltage (V), wire feed-rate (F), welding speed (S) and nozzleto-plate distance (N);
(3) developing the design matrix;
(4) conducting the experiments as per the design matrix;
(5) recording the responses, viz., penetration (P), weld width (W), reinforcement (R), and dilution (D);
(6) development of mathematical models;
(7) calculating the coefficients of the polynomials;
(8) checking the adequacy of the models developed;

770

N. Murugan et al./ Single wire surfacing

Table 1
Control parameters and their levels
Parameter
open-circuit voltage
feed rate
welding speed
nozzle-to-plate
distance

Unit
V
m/min
m/rain
mm

Notation

V
F
S
N

Factor levels
2
~
36
1.26
0.40
30

38
1.52
0.56
:~

o
~0
I78
0.72
38

2:

42
2.(}4
0.88
42

~.
!i~
i~!i
4~

(9) t e s t i n g the significance of the r e g r e s s i o n coefficients and a r r i v i n g at the

final m a t h e m a t i c a l models;
(10) p r e s e n t i n g the m a i n effects and the significant i n t e r a c t i o n s b e t w e e n ditf e r e n t p a r a m e t e r s in g r a p h i c a l form;
(11) a n a l y s i s of results.

2.1. Identification of the process variables

The i n d e p e n d e n t l y c o n t r o l l a b l e process p a r a m e t e r s were identified to e n a b l e
the c a r r y i n g out of the e x p e r i m e n t e d w o r k a n d the d e v e l o p m e n t of the mathe m a t i c a l models: t h e y w e r e o p e n - c i r c u i t v o l t a g e (V), wire feed-rate (F),
welding speed (S), and nozzle-to-plate d i s t a n c e (N). The e x p e r i m e n t s were
c o n d u c t e d by l a y i n g four beads w i t h a positive e l e c t r o d e and a c o n s t a n t
o v e r l a p of 2 to 3 mm. T h e r e s p o n s e s were m e a s u r e d a f t e r c r o s s - s e c t i o n i n g the
o v e r l a y at its mid-point. Hence, all the process v a r i a b l e s and the r e s p o n s e s
r e q u i r e d for the i n v e s t i g a t i o n w e r e identified.

2.2. F i n d i n g the limits of the process variables

T r i a l r u n s were c a r r i e d out by v a r y i n g one of the process p a r a m e t e r s whilst
k e e p i n g the rest of t h e m at c o n s t a n t v a l u e s [12]. The w o r k i n g r a n g e was
decided u p o n by i n s p e c t i n g the b e a d for a s m o o t h a p p e a r a n c e a n d the a b s e n c e
of a n y visible defects, viz., s u r f a c e porosity, u n d e r c u t , etc. The u p p e r limit of
a f a c t o r was coded as + 2 and the l o w e r limit as - 2 , the coded v a l u e s for
i n t e r m e d i a t e v a l u e s b e i n g c a l c u l a t e d from the following r e l a t i o n s h i p :
X; = 2 1 2 X - (Xmax + Zmin)]/(Zmax

Zmin)

w h e r e Xi is the r e q u i r e d coded v a l u e of a v a r i a b l e X; X is a n y v a l u e of the

v a r i a b l e f r o m Xmi. to Xmax; Xmi, is the l o w e r level of the v a r i a b l e a n d Xmax is the
u p p e r level of the v a r i a b l e . T h e decided levels of the process p a r a m e t e r s w i t h
t h e i r u n i t s and n o t a t i o n s a r e g i v e n in T a b l e 1.

N. Murugan et al./Single wire surfacing

771

Table 2
Design matrix and observed values of bead dimensions
S1. No.

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31

Design matrix
V

1
1
1
1
1
1
- 1
1
- 1
1
1
1
1
1
]
1
- 2
2
0
0
0
0
0
0
0
0
0
0
0
0
0

- 1
- 1
1
1
1
- 1
1
1
- 1
- 1
1
1
1
-1
1
1
0
0
-2
2
0
0
0
0
0
0
0
0
0
0
0

- 1
1
- 1
- 1
1
- 1
- 1
- 1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
-2
2
0
0
0
0
0
0
0

1
1
1
1
1
1
1
1
- 1
- 1
1
- 1
1
1
1
1
0
0
0
0
-2
2
0
0
0
0
0
0
0
0
0

Penetration
(mm)

Reinforcement
(mm)

Width
(mm)

Dilution
(%)

2.763
2.7
3.25
4.375
2.25
2.05
2.85
2.775
2.275
2.35
3.425
3.25
2.3
2.125
2.775
2.55
2.9
2.625
1.925
4.15
3.65
2.45
3.1
2.513
2.9
2.5
2.525
2.525
2.425
2.5
2.9

3.225
2.65
4.075
3.125
2.4
2.025
2.675
3.1
2.775
2.725
3.575
3.1
2.4
2.225
3.0
2.625
2.9
2.525
2.5
2.975
3.925
2.5
2.6
2.625
2.65
2.6875
2.3
2.625
2.6
2.775
2.75

36.9
41.3
39.1
45.2
27.9
36.4
32.1
33.6
38.5
44.0
41.4
43.0
30.0
31.4
29.4
33.2
36.5
43.3
33.7
37.7
45.8
29.0
40.5
39.0
39.8
36.3
38.2
37.3
36.6
37.2
39.6

38.95
4'2.99
36.95
54.68
41.55
40.5
46.64
38.69
37.48
37.43
42.01
42.95
40.41
41.9
41.96
42.85
42.65
42.63
36.6
52.14
41.59
43.43
45.58
39.81
46.05
43.05
45.74
42.53
41.05
42.5
45.83

2.3. Developing the design matrix

T h e s e l e c t e d d e s i g n m a t r i x , s h o w n i n T a b l e 2, i s a c e n t r a l

composite rotat-

a b l e f a c t o r i a l d e s i g n [13] c o n s i s t i n g o f 31 s e t s o f c o d e d c o n d i t i o n s . I t c o m p r i s e s
a full replication

o f 24 ( = 16) f a c t o r i a l d e s i g n p l u s 7 c e n t r e p o i n t s a n d 8 s t a r

p o i n t s . A l l w e l d i n g v a r i a b l e s a t t h e i n t e r m e d i a t e (0) l e v e l c o n s t i t u t e t h e c e n t r e
points and the combinations of each of the welding variables at either its
l o w e s t ( - 2 ) o r h i g h e s t ( + 2) w i t h t h e o t h e r t h r e e v a r i a b l e s o f t h e i n t e r m e d i a t e
l e v e l s c o n s t i t u t e t h e s t a r p o i n t s . T h u s t h e 31 e x p e r i m e n t a l r u n s a l l o w e d t h e
estimation of the linear, quadratic and
welding variables on the bead geometry.

two-way

interactive

effects of the

N. Murugan et al./ Single wire surfacing

772

Electrode
Flux

Wire reel

wire --~

Cantr o1
system7
\

/Wire

Paw e r

sourceff

- - J J , , oo o 9 r l

read

Auto-torch

Direction

travel

.:,ux

JL=

I II

| J 1

Work l e a d ~

'

+__

Base metal/~
Fig. 2. Surfacing by the submerged arc welding process.

2.4. Conducting the experiment as per the design matrix

F i g u r e 2 shows the s c h e m a t i c e x p e r i m e n t a l set-up for t y p i c a l single-wire
s u r f a c i n g by an a u t o m a t i c S A W unit, with a p o w e r s o u r c e of c o n s t a n t p o t e n t i a l
rectifier type h a v i n g 600 A c a p a c i t y . The e x p e r i m e n t s were c o n d u c t e d as per
the design m a t r i x at r a n d o m , to a v o i d s y s t e m a t i c e r r o r s i n f i l t r a t i n g the system.
A u t o m e l t 316L ss wire of 3.15.mm d i a m e t e r a n d ss flux g r a d e I were used to
deposit ss o n t o s t r u c t u r a l steel p l a t e IS 2062 of 20 m m t h i c k n e s s . K e e p i n g the
p o s i t i v e polarity, four b e a d s e a c h of 150 m m l e n g t h w i t h an o v e r l a p of 2 to 3 ram
w e r e laid.
2.5. Recording of the responses
T h e s u r f a c e d p l a t e s w e r e cross-sectioned at t h e i r mid-points to o b t a i n test
s p e c i m e n s 10 m m wide. T h e s e s p e c i m e n s were p r e p a r e d by the u s u a l m e t a l l u r
gical p o l i s h i n g m e t h o d s a n d e t c h e d w i t h 2% nital. T h e weld-bead profiles were
t r a c e d u s i n g a n optical profile p r o j e c t o r and the b e a d dimensions, viz., width,
p e n e t r a t i o n , and r e i n f o r c e m e n t , w e r e m e a s u r e d . W i t h the help of a p l a n i m e t e r .
the a r e a s of t h e p a r e n t p l a t e m e l t e d a n d the weld m e t a l f o r m i n g the reinforcem e n t w e r e m e a s u r e d and the p e r c e n t a g e d i l u t i o n was c a l c u l a t e d . T h e o b s e r v e d
v a l u e s of W, P a n d R and c a l c u l a t e d v a l u e s of dilution a r e g i v e n in T a b l e 2.
2.6. Development of mathematical models
T h e r e s p o n s e f u n c t i o n r e p r e s e n t i n g a n y of the weld-bead d i m e n s i o n s can be
e x p r e s s e d [12] as Y = f ( V , F , S,N), the r e l a t i o n s h i p selected b e i n g a second-

N. Murugan et al./Single wire surfacing

773

Table 3
Estimated values of the coefficients of the models
S1. No.

Coefficient

Penetration
(P)

Reinforcement
(R)

Width
(W)

Dilution
(D)

1
2
3
4
5
6

b0

b22

8
9
10
11
12
13
14
15

b33
ba4
b12
bl3
bl~
b23
b24
b34

2.611
0.0109
0.453
-0.296
0.131
0.0113
0.08
0.083
0.0222
0.063
-0.102
0.08
-0.124
0.0336
0.1008

2.627
0.1375
0.242
-0.3188
-0.0333
0.0277
0.0339
0.1527
0.0268
0.0125
0.0969
0.025
0.0094
-0.0313
0.0594

37.857
1.933
0.775
-4.542
-0.1917
0.2232
0.8268
-0.4018
0.1857
-0.425
-0.150
-0.5125
-0.3375
-0.275
0.65

43.821
0.667
2.358
0.1975
- 1.0625
0.5133
-0.0808
0.5458
0.4995
0.449
- 1.830
0.5938
-0.8725
-0.0263
0.840

bl
b2
b3
b4
bll

degree response surface expressed as follows:

Y=bo +bl V + b 2 F + b 3 S + b a N + b l l V2 +b22F2 +b33S2 +b44N2 +b12 V F

+b13 V S+b14 V N+b23F S+b2aF N+b3aS N
2. 7. Evaluation of the coefficients of models
The values of the coefficients were calculated by regression with the help of
t h e f o l l o w i n g e q u a t i o n s [14]:
b0 =0.142857 ~ Y - 0 . 0 3 5 7 1 4 ~ ( X ,

Y)

b, = 0.041667 ~ ( X , Y)
b, = 0.03125 ~ (X,, Y) - 0.035714 ~

(X,, Y) - 0.035714 ~ Y

b,j = 0.0625 ~(Xij Y)

A c o m p u t e r p r o g r a m m e w a s d e v e l o p e d to c a l c u l a t e t h e v a l u e o f t h e s e coeffic i e n t s for d i f f e r e n t r e s p o n s e s , t h e v a l u e s b e i n g p r e s e n t e d i n T a b l e 3.

2.8. Checking the adequacy of the developed models

The adequacy of the models was then tested by using the analysis of variance
t e c h n i q u e ( A n o v a ) [13,14]. A s p e r t h i s t e c h n i q u e : (i) t h e c a l c u l a t e d v a l u e o f t h e
F-ratio of the model developed does not exceed the standard tabulated value of
F - r a t i o f o r a d e s i r e d l e v e l o f c o n f i d e n c e ( s a y 95%); a n d (ii) if t h e c a l c u l a t e d
value of the R-ratio of the model developed exceeds the standard tabulated

of variance

SS
1.1
0.92
45.3
105.1

DF

4
4
4
4

7.46
4.32
600
172

10
IO
10
10

DF

of models

2nd order
terms

adequacy

ss

First order
terms

for testing

0.69
0.66
35.4
166

ss

Lack of
fit

R-ratio = MS of first and second order terms/MS of error.

mean square.
degree of freedom; MS
SS
sum of squares; DF
R-ratio,,,.,,,i,=3.96.
F-ratio ,,n,h,ooil=4.09:

penetration
reinforcement
width
dilution

Bead geometry
parameters

Calculation

Table 4

0.24
0.15
11.68
24.37

10

SS

10
70
10

DF

Error
terms

6
6
6

DF
15.23
15.10
23.68
4.89

4.09

R-ratio

1.71
2.65
1.82

F-ratio

adequate

adequate
adequate
adequate

Whether model
is adequate

5
_1

N. Murugan et al./Single wire surfacing

775

value of the R-ratio for a desired level of confidence (say 95%) t h e n the model
may be considered a d e q u a t e within the confidence limit. F r o m Table 4, it has
been found t h a t all models are adequate.

2.9. Testing the coefficients for significance

The v a l u e of the regression coefficients gives an idea as to w h a t e x t e n t the
control variables affect the responses q u a n t i t a t i v e l y . Insignificant coefficients
can be eliminated along with responses with which they are associated, without sacrificing m u c h of the accuracy, to avoid c u m b e r s o m e m a t h e m a t i c a l
labour. To achieve this, student's t-test is used [14]. According to this test,
when the c a l c u l a t e d value of t c o r r e s p o n d i n g to a coefficient exceeds the
s t a n d a r d t a b u l a t e d value for the desired level of probability (say 95%), the
coefficient becomes significant. After d e t e r m i n i n g the significant coefficients,
the final models were developed using only these coefficients.
2.10. Development of final models
The final m a t h e m a t i c a l models as d e t e r m i n e d by the above analysis are
r e p r e s e n t e d below:
P = 2.6107 + 0.4536 F - 0.2964 S - 0.1307 N - 0.1242 F S
R=2.6268

0 . 1 3 7 5 V + 0 . 2 4 1 7 F - 0 . 3 1 8 8 S + 0 . 0 9 6 9 VS+0.1527S 2

W= 37.857 - 1.933 V + 0.775 F - 4.542 S - 0.8268 F 2

D = 43.821 + 2 . 3 5 8 F - 1 . 0 6 2 5 N - 1.83 V S
3. R e s u l t s

The m a t h e m a t i c a l models furnished above can be used to predict the weldbead g e o m e t r y by substituting the values, in coded form, of the respective
factors. The responses c a l c u l a t e d from these models for each set of coded
welding variables are r e p r e s e n t e d in graphical form in Figs. 3 to 9. Also, by
s u b s t i t u t i n g the values of the desired bead geometry, the values of the control
factors, in coded form, can be obtained.
4. D i s c u s s i o n

The main effects of the different process variables on the weld-bead dimensions predicted from the m a t h e m a t i c a l models using the e x p e r i m e n t a l observations are depicted in Figs. 3 to 9, these showing the generally c o n v i n c i n g
trends between cause and effect.

4.1. Direct effects of parameters

F r o m Fig. 3, voltage (V) has no significant effect on p e n e t r a t i o n (P). Reinf o r c e m e n t (R) decreases with increase in V but the reverse is t r u e with width

776

N. Murugan et al./Single wire surfacing

3.0
/+I

2, x \

39
2E

2.6
37~-

o_"
35

2.2
35

37

(-2)

39

/.1

1,3

33
~,5

(-I)
(0)
(I)
(2)
0PEN CIR(UIT VOLTAGE

Fig. 3. Effect of variation in the voltage. (F= 1.78 m/min; S=0.72 m/min; N= 38 ram!

3.6

/.7S
3.1
o_

/,2.5
o~

2.6

:IE
:IE
3~

3"/.5

2.1

1.6

"~

1.2
1-2)

If

I./+6
(-I}
FEED

1.72
(0)
RATE

1.98
|I)

32.5

2.2/+
{2)

H/HIN

Fig. 4. Effect of variation in the feed rate. (OCV=40 V: S=0.72 m/min; N=38 ram)

(W). F r o m Fig. 4, P, R and D increase with increase in feed rate (F) but
W decreases after r e a c h i n g an o p t i m u m value. F r o m Fig. 5, P and W decrease
with i n c r e a s e in speed but R decreases to an o p t i m u m v a l u e with increase m
speed. F r o m Fig. 6, nozzle-to-plate d i s t a n c e (N) has no effect on R and W but
P and D decrease with i n c r e a s e in N.

N. Murugan et al./Single wire surfacing

777

~3
325

38

o..

2.75

33

2.25

.)(.

1.75
0-36
(-2)

, i
i ,
~ ,
0.52
0-68
0.86
{-1)
(0)
(1)
SPEED H / NIN

'
28
1.00
(2)

Fig. 5. Effect of variation in the speed. (OCV =40 V; F= 1.78 m/min; N= 38 ram)

3.0

~.7

~2.8

~5

2.6

"~",~~x

~3

2.6

-)6

2.0

29
(-2)

33
(-1)

37
{0)

"

,)~

~1
[1)

3"/

~,5
(2)j
MH

Fig. 6. Effect of variation in the nozzle-to-plate distance. (OCV=40V; F=1.78m/min;

S=0.72 m/rain)

4.2. Interaction effects of process parameters on dilution

F r o m Fig. 7, it is c l e a r t h a t the dilution is not affected by the c h a n g e s in
v o l t a g e provided t h a t the speed is k e p t at the 0 level. W h e n S is c h a n g e d from
the 0 level, D h a s two e n t i r e l y different and opposite trends: w h e n S is below

N. Murugan et a/./Single wire surfacing

778
S/,

S=-2
x

/*9

//~S.-- -1

Z- /.6,

S=2
3/*

35

37

39

/.1

/*3

/*S

(-2)
(-1)
0
(-1)
(-2)
OPEN CIRCUIT VOLTAGE VOLTS

Fig. 7. E f f e c t o f v a r i a t i o n in t h e v o l t a g e o n p e r c e n t a g e d i l u t i o n . ( F = ] .78 m / r a m : N ~ : ~ ram)

All fQctors at

/*9

_x01Level

"=39 x

3/*

29, i
1.2
(-2)

, t
1./.6
(-1)
FEED

4 p
= I
1.72
198
(0)
(1)
RATE H / H t N

, l
2.2/,
(2)

Fig. 8. E f f e c t o f v a r i a t i o n in t h e f e e d r a t e o n p e r c e n t a g e d i l u t i o n .

the 0 level D i n c r e a s e s w i t h i n c r e a s e in V b u t w h e n S is a b o v e the 0 level

D d e c r e a s e s w i t h i n c r e a s e in V. This is due to the h e a t i n p u t to the s y s t e m
i n c r e a s i n g w h e n the welding speed decreases, h e n c e m e l t i n g of m o r e base
m e t a l r e s u l t i n g in m o r e dilution.

N. Murugan et al./Single wire surfacing

hit factors

~ a

779

Qt

Level
Level
Level

~38
-1

Level

33
Level
Z8
I
29

I I

33
37
G1
~,S
l-2)
l-1)
{0)
(1)
(2)
NOZZLE-TO-PLATE DISTANEE MM

Fig. 9. Effect of variation in the nozzle-to-plate distance on percentage dilution.

F r o m Fig. 8, D is highest w h e n all factors are at the 0 level and F is at its + 2

level but it is least when all factors are at the + 2 level and F i s at the - 2 level.
F r o m Fig. 9, D is highest when all factors are at the + 1 or the 0 level and N is
atthe
21evel but it is least when all factors are at the - 21evel and N is at the
+ 2 level.

5. C o n c l u s i o n s
The following c o n c l u s i o n s were arrived at from the above investigations:
(1) The five level factorial t e c h n i q u e can be employed easily for developing
m a t h e m a t i c a l models for predicting weld-bead g e o m e t r y within the optimal
region of control p a r a m e t e r s or o p e r a t i n g variables for single wire ss surfacing.
(2) The models developed can be employed easily in a u t o m a t e d or robotic
welding, in the form of a program, for o b t a i n i n g the desired high q u a l i t y welds.
(3) P e n e t r a t i o n is not affected significantly by voltage and nozzle-to-plate
distance and width is not affected by the latter.
(4) Dilution increases with increase in voltage when the speed is from the
- 2 to the 0 level and D is not affected by c h a n g e s in V w h e n the speed is at the
0 level. D decreases with increase in V when the speed is from the 0 to the + 2
level.
(5) Dilution is least w h e n all factors are at the + 2 level and F is at the - 2
level, as well as when all factors are at the - 2 level and N is at the + 2 level.

N. Murugan et al./Single wire sur[hcing

780

References
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
[10]
[11]
[12]
[13]
[14]

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P.T. Houldcroft, Submerged-Arc Welding, Abington Publishing, UK, 1989.
Hallock, H.C. Campbell and W.C. Johnson, Am. Weld. J., 45 (1966) 399.
Stan Grainger, Engineering Coatings, Abington Publishing, UK, 1989.
American Society For Metals, Metals Hand Book, Vol. 6, Metals Park. OH. 1982
J.C. McGlone, Met. Constr., 14 (1982) 378.
Y.P. Adler, E.V. Markov and Y.V. Granovsky, 2'he Design of Experiments W ti~d
Optimal Conditions, MIR Publishers, Moscow, 1975.
P. Harris and B.L. Smith, Met. Constr., 15 (1983) 661.
D.V. Smith, Am. Weld. J., 67 (1988) 57.
J.F. Lancaster, Metallurgy of Welding, Allen & Unwin, I,ondon, 1987.
B.T. Nugent, Met. Constr., 14 (1982) 241.
V.K. Gupta and R.S. Parmar, Fractional factorial technique to predict dimensions of the
weld bead in automatic submerged arc welding, J. Inst. Eng. (India), 70 (1989) 67.
William G. Cochran and Gertrude M. Cox, Experimental Designs. Asia Publishing
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O.L. Davies, The Design and Anatvsis of Industrial Experiments, Longman, New "~'ork.
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