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The E Ect of Process Parameters On Penetration in Gas Metal Arc Welding Processes
The E Ect of Process Parameters On Penetration in Gas Metal Arc Welding Processes
& Design
Materials and Design 28 (2007) 649–656
www.elsevier.com/locate/matdes
a
Sakarya University, Engineering Faculty, Department of Mechanical Engineering, Esentepe Campus, 54187 Sakarya, Turkey
b
Sakarya University, Technical Education Faculty, Department of Metal Education, 54187 Sakarya, Turkey
c
ISE Automotive Company, Aksaray, Turkey
Abstract
In this study, the effects of various welding parameters on welding penetration in Erdemir 6842 steel having 2.5 mm thickness
welded by robotic gas metal arc welding were investigated. The welding current, arc voltage and welding speed were chosen as var-
iable parameters. The depths of penetration were measured for each specimen after the welding operations and the effects of these
parameters on penetration were researched.
The welding currents were chosen as 95, 105, 115 A, arc voltages were chosen as 22, 24, and 26 V and the welding speeds were
chosen as 40, 60 and 80 cm/min for all experiments. As a result of this study, it was obvious that increasing welding current increased
the depth of penetration. In addition, arc voltage is another parameter in incrimination of penetration. However, its effect is not as
much as currentÕs. The highest penetration was observed in 60 cm/min welding current.
2005 Elsevier Ltd. All rights reserved.
0261-3069/$ - see front matter 2005 Elsevier Ltd. All rights reserved.
doi:10.1016/j.matdes.2005.07.014
650 E. Karadeniz et al. / Materials and Design 28 (2007) 649–656
Table 1
The chemical compositions of the specimens, wt%
C Mn Si S P
Base-metal (Erdemir 6842- DIN EN 10120) 0.16 0.72 0.07 0.004 0.013
Wire electrode (G3Si 1-DIN EN 440) 0.077 1.41 0.86 0.012 0.014
E. Karadeniz et al. / Materials and Design 28 (2007) 649–656 651
Table 2
The depth of penetration results of welding operations
Welding current Arc voltage Welding speed Penetration
(A) (V) (cm/min) (mm)
95 22 40 2.46
60 2.51
80 2.36
24 40 2.61
60 2.67
80 2.56
26 40 2.64
Fig. 2. A schematic illustration of bead geometry [14]. 60 2.69
80 2.59
CO2 mixture, nozzle opening is 10 mm, the free wire 105 22 40 2.84
length is 15 mm wire feeding rate is 12 m/min, arc dis- 60 2.92
80 2.79
tance is 3 mm and the torch angle is 5. The variable 24 40 2.89
parameters are; welding current (I) as 95, 105 and 60 2.97
115 A, arc voltage (V) as 22, 24 and 26 V, the welding 80 2.84
speed (S) as 40, 60 and 80 cm/min selected for the weld- 26 40 2.98
ing experiments. 60 3.01
80 2.91
Having finished the welding processes, the specimens
were cut perpendicular to welding direction by using a 115 22 40 3.02
60 3.06
closed circuit saw cooled by boron oil in order to mea-
80 2.94
sure the depth of penetration. The cut surfaces were 24 40 3.11
grained with 600, 800 and 1200 numbered grinding pa- 60 3.14
per and etched with 10% HNO3 solution. The macro- 80 3.04
structure photos were taken from these etched surfaces 26 40 3.19
60 3.24
by means of a Nikon Stereo Zoom optical microscope
80 3.16
in 10· magnification. The penetration measurements
were done from macro-structure photos by using a
new vision program. A schematic illustration of bead
3.3
penetration in welding applications was shown in Fig. 2.
3.1
Penetration(mm)
3.3 3.3
Pm(noitartenem)
3. 2
3.1
3.1
Penetration (mm)
3 2.9
2.9
2.7
2.8
2.7 2.5
2.6 2.3
2.5 21 22 23 24 25 26 27
2.4 Arc Voltage (V)
2.3
90 95 100 105 110 115 120 95 A 105 A 115 A
Penetration(mm)
3.1
3.3 2.9
3.2
2.7
3.1
Penetration(mm)
3 2.5
2.9
2.3
2.8
21 22 23 24 25 26 27
2.7
2.6 Arc Voltage (V)
2.5 95 A 105 A 115 A
2.4
2.3 Fig. 7. Penetration vs. arc voltage diagram for 60 cm/min constant
90 95 100 105 110 115 120 welding speed.
Welding Current (A)
22V 24V 26V
3.3
Fig. 5. Penetration vs. welding current diagram for 80 cm/min welding
Penetration(mm)
3.1
speed.
2.9
2.7
80 cm/min this range was higher in between 95 and
2.5
105 A. After 105 A, it shows a linear increment trend
as in Figs. 3 and 4. This situation is convenient with 2.3
21 22 23 24 25 26 27
the literature [2,18]. Arc Voltage (V)
A linear increase in depth of penetration with increas-
95 A 105 A 115 A
ing welding current was observed commonly in all three
different welding speeds. These measured values in pen- Fig. 8. Penetration vs. arc voltage diagram for 80 cm/min constant
etration for each 1 A current rise in 40, 60 and 80 cm/ welding speed.
min were 0.0235, 0.0217 and 0.0225 mm, respectively.
voltages between 22 and 26 volt range and increase in
3.2. The effect of arc voltage on penetration depth of penetration is 0.18 mm for 95 A, 0.09 mm
for 105 A and 0.18 mm for 115 A.
The effect of arc voltage on penetration was com- In Fig. 8, there is a similar trend observed in Figs. 6
mented to the results shown in Table 2 and Figs. 6–8. and 7. Increased penetration values were 0.23, 0.12 and
It was seen in Fig. 6 that the depth of penetration val- 0.22 mm in 95, 105 and 115 A, respectively. The depth of
ues were increased with increasing arc voltages for 95, penetration increases with increasing arc voltage linearly
105 and 115 A and these were 0.18, 0.14 and 0.17 mm in three figures; however, these values are very low com-
in 95, 105 and 115 A, respectively, for a 4 V increment paring to welding current vs. penetration figures.
between 22 and 26 V arc voltages. However, these are
very low values for 40 cm/min constant welding speed. 3.3. The effect of welding speed on penetration
This situation was approximately same for a 60 cm/
min constant welding speed given in Fig. 7. A linear The graphs of penetration vs. welding speed were
penetration increase was observed with increasing arc drawn in 22, 24 and 26 V constant arc voltages for 95,
E. Karadeniz et al. / Materials and Design 28 (2007) 649–656 653
105 and 115 A values. These were shown in Figs. 9–11. sured by a new vision program in 10· magnification.
The depth of penetration increases with increasing weld- The resulted photographs were given in Figs. 12–21.
ing speed up to 60 cm/min point which was the optimum In the light of macro-structure photos; reliable bead
value to obtain maximum penetration, because it begins heights and depth of penetration values were obtained
to decreasing after this point again linearly. This condi-
tion is convenient with the literature [5,18].
3.4. Macrostructure
3.1
Penetration(mm)
2.9
2.7
2.5
Fig. 12. 95 A, 24 V, 60 cm/min condition. Depth of penetration,
P = 2.67 mm.
2.3
30 40 50 60 70 80 90
Welding Speed (cm/min)
95 A 105 A 115 A
3.3
Penetration(mm)
3.1
2.9
2.7
2.5
2.3
30 40 50 60 70 80 90
Fig. 13. 95 A, 26 V, 40 cm/min condition. P = 2.64 mm.
Welding Speed (cm/min)
95 A 105 A 115 A
Fig. 10. Penetration vs. welding speed diagram for 24 V constant arc
voltage.
3.3
Penetration(mm)
3.1
2.9
2.7
2.5
2.3
30 40 50 60 70 80 90
Welding Speed (cm/min)
95 A 105 A 115 A
Fig. 11. Penetration vs. welding speed diagram for 26 V constant arc
voltage. Fig. 14. 95 A, 26 V, 60 cm/min condition. P = 2.69 mm.
654 E. Karadeniz et al. / Materials and Design 28 (2007) 649–656
Acknowledgements
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