Materials Today: Proceedings 44 (2021) 900–908

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Materials Today: Proceedings

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Prediction of bead geometry parameters in MIG welded stainless steel

409L plates by mathematical modelling
Rishabh Narang ⇑, Vibhu Maheshwari, Pradeep Khanna
Department of Manufacturing Processes and Automation Engineering, Netaji Subhas University of Technology, New Delhi 110078, India

a r t i c l e i n f o a b s t r a c t

Article history: Metal inert gas (MIG) welding is considered to be a preeminent welding process due to its compatibility
Received 20 September 2020 towards adapting automated applications in fabrication works. In present investigation, butt joint weld-
Received in revised form 21 October 2020 ing was performed on ferritic stainless-steel plates of grade 409L in order to predict weld bead geometry
Accepted 27 October 2020
parameters. Weld bead geometry influences the mechanical strength of the joint; therefore it must be of
Available online 17 December 2020
desired dimensions. It has been found that bead geometry depends upon the value of input parameters.
Therefore, to obtain a sound weld joint, it is essential to determine the best combination of input param-
Keywords:
eters. An attempt is made to establish a mathematical relationship between the input and response
GMAW
Bead geometry
parameters and the response parameters in this case are weld width (W), height of reinforcement (H)
Mathematical equation and depth of penetration (D). The mathematical equation was generated using Taguchi statistical tech-
Response surface methodology nique and the adequacy of the developed equation was examined using analysis of variance (ANOVA)
ANOVA approach. The design of experiments (DOE) method was employed to conduct the experiments in a
methodical manner and response surface methodology (RSM) was used for graphical optimization.
Weld bead geometry can be predicted accurately by selecting appropriate process parameter values
determined by the generated models.
Ó 2021 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the International Confer-
ence on Materials, Processing & Characterization.

1. Introduction Bead geometry is itself governed by the selection of welding

MIG welding is a popular method for achieving coalescence of
metals for industrial applications [1]. Due to its growing demand
in automated welding systems, it plays an essential role in the
sheet metal industry [2]. MIG welding input parameters have an
impact on quality, productivity and cost of welding joints. In order
to achieve a perfect arc all the welding parameters should be con-
formity [3]. The chief factors which contribute to its widespread
use for various industrial applications include multi position weld
capability, high productivity, slag-free and strong welds [4].
Construction and manufacturing costs of steel structures is
directly affected by weld bead geometry [5]. Weld geometry also
shows significant effect on the load bearing capability of a welded
joint, which determines the performance in real time service con-
ditions [6]. Thus, it is essential to obtain optimum weld bead
geometry in order to produce a weld with desired mechanical
properties [7].
⇑ Corresponding author.
E-mail address: rishabhn.bt.17@nsit.net.in (R. Narang).
parameters which are wire feed rate (WFR), welding speed (S),
voltage (V), nozzle to plate distance (NPD) and torch angle (h)
[5]. Several studies in the past have made an attempt to develop
statistical models in order to correlate the weld bead geometry
with welding parameters; hence it is required to establish a metic-
ulous relationship between them [7]. Present investigative work
focuses on analyzing the influence of input parameters on various
response parameters such as bead width (W), depth of penetration
(P) and height of reinforcement (H) as depicted in Fig. 1 [2].
If an accurate model can be predicted for the relationship
between the input parameters and the bead geometry then the
required bead geometry can be obtained by adjusting the input
parameters [8]. Statistical technique developed by Taguchi was
employed to formulate the mathematical equation. Taguchi based
DOE approach is used in order to obtain an economical solution for
process design optimization projects [9]. A multi-response opti-
mization model was used to develop a parametric combination
to yield favourable bead geometry. The adequacy of the developed
equation and computation of graphical analysis was done using
ANOVA and RSM respectively [8].

https://doi.org/10.1016/j.matpr.2020.10.795
2214-7853/Ó 2021 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the International Conference on Materials, Processing & Characterization.
R. Narang, V. Maheshwari and P. Khanna Materials Today: Proceedings 44 (2021) 900–908

Fig. 1. Weld bead geometry.

Experiments were performed on titanium stabilized ferritic SS

409L constituting about 11% chromium. Chromium helps in form-
ing of a passive surface film thereby making it corrosion resistant
[10]. The presence of small amount titanium prevents inter granu-
lar corrosion which caused by formation of chromium carbide.
Resistance to pitting corrosion is improved due to presence of tita-
Fig. 2. Experimental arrangement.
nium and sulphur together [11,12]. Atmospheric corrosion resis-
tance of this grade is nearly 250 times that of MS. This grade has (b) Working limits of parameters
wide application where good formability and weldability are
required in such mildly corrosive environments. Due to its proper- Test runs were performed by varying one of the input parame-
ties like corrosion resistance and ease of fabrication have signifi- ters, while keeping the rest of them constant. The working range of
cantly broadened its utilization in industrial applications. Its each parameter was divided into 5 different levels. The values at
typical applications are automotive exhaust tubing, catalytic con- extreme levels were selected on basis of the criteria:
verter systems, mufflers [13,14].
 Defect less weld
 Spatter free
2. Experimental details  Stabilized arc

2.1. Materials and experimental arrangement
The machine has a rating of 400 A, 100% duty cycle and flat V-I
characteristics suitable for performing semi-automatic and fully
automatic welding. In order to ensure uniform quality of weld at
different preset values of welding speed, ranging from 0 to
50 cm/sec, a motor driven mechanized carriage unit was
employed. The experiments were performed on plates of SS 409L
with dimension 200
150
6 mm and filler metal of SS 308L with
1.2 mm diameter was used. Industrially pure argon at a flow rate of
16 L/ minute was used as the shielding gas. Shielding gas assists
with stabilizing the arc and prevents from atmospheric contamina-
tion [5].
The chemical composition of SS 409L and SS 308L are given in
Table 1.
The complete experimental arrangement has been illustrated in
Fig. 2.
2.2. Experimental procedure
The experimental procedure followed is given below:
(a) Input parameters identification
Intermediate values were calculated using the below given
formula:
2½2X  ðXmax þ XminÞ
Xi ¼
Xmax  Xmin
Where Xmax and Xmin are the maximum and minimum values at the
maximum and minimum level; X is any value of the variable
between Xmax and Xmin; and Xi is the coded value to be determined.
Table 2 represents various combinations for experimentation [8]. It
is noted that all the process parameters are maintained at all possi-
ble combinations of the 5 levels of parameters, thus simulating the
actual experimental condition [15,16].
(c) Design Matrix
Design matrix was formulated using the design of experiments
(DOE) technique. Central composite face centred design (CCFD)
was implemented to formulate a model consisting of a total 32
runs. The experiments were carried out in accordance with the
design matrix. The runs generated were divided as 25-1 = 16 runs
using half factorial, 2*5 = 10 runs using star points and the rest 6
runs using centre points. Table 3 shows the developed design
matrix [2,7].

Evident by product of literature and some initial test runs, five
independent controllable input parameters were deduced namely
‘‘wire feed rate (m/min)”, ‘‘welding speed (cm/min)”, ‘‘voltage
(V)”, ‘‘nozzle to plate distance (mm)” and ‘‘torch angle (degree)”
which had were found to have significant effect on weld bead
geometry.
(d) Experimentation
Plates of dimension 200
150
6 mm were cleaned using
emery paper. The experiments were carried out in a desultory
manner to eliminate any systematic error. a specimen size of
60
30
6 mm was obtained by cutting each welded piece and

Table 1
Composition of SS 409L and 308L (Provided by supplier).

Element C Mn P S Si Cr Ni Cu Mo Ti N (ppm)
SS 409L (wt. %) 0.0069 0.256 0.307 0.007 0.475 11.243 0.054 0.017 0.009 0.2033 51
SS 308L (wt. %) 0.018 1.9 0.017 0.010 0.32 19.7 10.10 – – – –

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R. Narang, V. Maheshwari and P. Khanna Materials Today: Proceedings 44 (2021) 900–908

Table 2
Input parameters and their limits.

Input parameters Units Limits

2 1 0 +1 +2
Wire Feed Rate (WFR) m/min 0.3 0.6 0.9 1.2 1.5
Welding Speed (WS) cm/min 30 35 40 45 50
Voltage (V) V 14 16 18 20 22
Nozzle to plate distance (NPD) mm 10 12.5 15 17.5 20
Torch Angle (TA) (°) 70 80 90 100 110

Table 3
Design matrix.

Run WFR (m/min) WS (cm/min) V (Volts) NPD (mm) TA (°) Width(mm) DOP(mm) HOR(mm)
1 1 1 1 1 1 9.5 3.1 1.9
2 0 2 0 0 0 4.6 2.6 2.1
3 1 1 1 1 1 7.8 2.9 1.5
4 1 1 1 1 1 6.7 3.7 1.3
5 1 1 1 1 1 6.7 6.1 0.9
6 0 0 0 0 2 4.3 2.6 1.4
7 0 0 0 0 0 7.4 2.2 1.8
8 0 2 0 0 0 6.6 2.7 2.1
9 0 0 2 0 0 6.5 3.5 1.9
10 1 1 1 1 1 7.6 2.1 1.7
11 0 0 0 0 0 7.8 2.6 2
12 0 0 0 0 0 7.6 2.8 1.8
13 0 0 0 0 0 7.5 2.5 1.8
14 2 0 0 0 0 7.6 4.9 1.7
15 0 0 0 2 0 9.5 3.4 2.3
16 2 0 0 0 0 3.2 0.9 1.7
17 1 1 1 1 1 8.7 3.2 1.3
18 0 0 2 0 0 4.7 2.9 1.1
19 0 0 0 0 0 7.9 3 1.6
20 1 1 1 1 1 7.7 3.2 1.5
21 1 1 1 1 1 12 2.9 2.6
22 1 1 1 1 1 7.8 3.3 1.4
23 1 1 1 1 1 10.4 6.3 0.7
24 0 0 0 0 0 7.7 3.4 1.3
25 1 1 1 1 1 9.2 5.1 2.7
26 0 0 0 2 0 10.3 3.2 2.2
27 1 1 1 1 1 11.2 4.7 1.8
28 0 0 0 0 2 8.1 4 2.2
29 1 1 1 1 1 8.4 5.7 2.4
30 1 1 1 1 1 9.8 5.8 1
31 1 1 1 1 1 9.5 3.1 2.3
32 1 1 1 1 1 7.7 2.7 2

then polished using a disc polishing machine. The polished pieces
were then etched. The etchant was prepared by adding 50 g FeCl3
and 120 ml HCl in 480 ml H20. The measurement of bead dimen-
sions was done using ImageJ software as illustrated in Fig. 3.
(e) Mathematical Model
Response surface function for each bead geometry characteris-
tics can be represented as:
X = f (a, b, c, d, e)
Y = f (a, b, c, d, e)
Z = f (a, b, c, d, e)
The equation generated by response function can be expressed
in terms of the independent parameters as:
b0 + b1a + b2b + b3c + b4d + b5e + b12ab + b13ac + b14ad + b15ae
+ b23bc + b24bd + b25be + b34cd + b35ce + b45de + b11a2 + b22b2 + -
b11a2 + b22b2 + b33c2 + b44d2 + b55e2 where:
Here ‘‘X”, ‘‘Y”, ‘‘Z” represents the bead width, depth of penetra-
tion, and height of reinforcement, respectively. Coefficients ‘‘a”, ‘‘
b’’, ‘‘ c’’, ‘‘ d” and ‘‘e” are the input parameters which denote ‘‘wire
feed rate”, ‘‘welding speed”, ‘‘voltage”, ‘‘NPD” and ‘‘torch angle”. b0
is the coefficient of model, b1, b2. . .bk are the coefficients of linear
terms, b12, b13. . .b(k-1)k are coefficients of interactive terms and b11,
b22. . .bkk are the coefficients of quadratic terms of the regression
equation.
Width ¼ 7:75 þ 0:8534A  0:4591B þ 0:8075C  0:2701D
þ0:4795E  0:1637AB þ 0:3988AC þ 0:1658AD
0:5342AE þ 0:1177BC  0:6121BD þ 0:7379BE  0:3405CD ð1Þ
þ0:1094CE  0:6906DE  0:7013A2 þ 0:2237B2 þ
0:1112C2 þ 0:4390D2 þ 0:0624E2
DOP ¼ 3:05 þ 0:7708A  0:0985B þ 0:2377C  0:6368D
þ0:1095E  0:0017AB  0:6362AC  0:0888AD þ 0:2352AE
þ0:1982BC  0:3483BD  0:0183BE  0:1387CD þ 0:0852CE
0:0853DE þ 0:1221A2 þ 0:0228B2 þ 0:1237C2 þ
0:4233D2  0:1772E2
ð2Þ

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R. Narang, V. Maheshwari and P. Khanna Materials Today: Proceedings 44 (2021) 900–908

Fig. 3. Measurement of bead geometry.

Table 4
ANOVA table.

Significance of model Lack of Fit

SS df MS F-Value p-value Whether Significant SS df MS F-Value p-value Whether Significant
DOP 43.67 20 2.18 20.39 0.00001 YES 0.7029 6 0.1171 1.23 0.4182 NO
Width 102.30 20 5.10 511.36 <0.00001 YES 0.0547 6 0.0091 0.8294 0.5931 NO
HOR 5.73 20 0.2867 3.92 0.0119 YES 0.4642 6 0.0774 1.14 0.4534 NO

HOR ¼ 1:57 þ 0:0809A  0:1659B  0:1841C þ 0:2507D
þ0:1409E þ 0:0386AB  0:0511AC þ 0:0761AD
0:0511AE  0:0364BC  0:2386BD þ 0:1136BE þ 0:0511CD
0:0261CE  0:0489DE þ 0:0398A2 þ 0:1048B2 þ
2 2 2
0:0173C  0:0327D þ 0:1048E
(f) Adequacy Test
The adequacy of the generated model was analyzed by compar-
ing the calculated F-ratio given by the software and the tabulated
value of F-ratio. If the latter value is greater than the former value,
the model can be said to be adequate.
In the present case the tabulated value of F-ratio at degree of
freedom 6 and 5 at a confidence level of 95% indicating that the
developed model is adequate. Secondly, the p-value of the devel-
oped model is also less than 0.05, confirming the adequacy of the
model as depicted in Table 4.
3. Results and discussion
3.1. Interactive effects of WFR & V on WIDTH
cient of A and C in mathematical equation (i) in section 2.2 (e) con-
firms the same.
ð3Þ
3.2. Interactive effects of WS & WFR on WIDTH
The surface plot in Fig. 5 illustrates the combined effect of WS
and WFR on bead width. It was inferred from the plot that with
increased values of WS there is a slight decrease in bead width
while with increased values of WFR there is an increase in bead
width. Probable reason for this could be that with increased WS
less heat per unit length was introduced into the weldment, reduc-
ing the maximum value of bead width even at maximum WFR The
negative coefficient of B and positive coefficient of C in mathemat-
ical equation (i) in section 2.2 (e) confirms the same.
3.3. Interactive effects of WS & V on WIDTH
The surface plot in Fig. 6 illustrates the combined effect of WS
and V on bead width. It was inferred from the plot that with
increased values of WS there is a slight decrease in bead width
while with increased values of Voltage there is an increase in bead
width. From the combined effect of both it was observed that with
increased voltage there was greater arc spread thereby increasing
the bead width even at higher values of welding speed.

The surface plot in Fig. 4 illustrates the combined effect of WFR
and voltage on bead width. It was inferred from the plot that with
increased values of both voltage and WFR, the bead width
increases. The probable reason for this could be at higher values
of voltage, there is an increase in arc spread which leads to an
increased bead width while with increase in WFR more amount
of filler wire melts, resulting in greater width. The positive coeffi-
903
3.4. Interactive effects of WFR & NPD on DOP
The surface plot in Fig. 7 illustrates the combined effect of WFR
and NPD on DOP. It was inferred from the plot that with increased
values of WFR there is an increase in DOP whereas with higher val-
ues of NPD there is a decrease in DOP. The probable reason for this
could be that with increased WFR there was more heat input into
R. Narang, V. Maheshwari and P. Khanna Materials Today: Proceedings 44 (2021) 900–908

the weldment, while with increased NPD there was preheating of in the interactive curve, it can be concluded that the combined
wire which prevented the fusion of the weld droplet with the base effect of NPD and TA results in decrease of DOP. The negative coef-
metal. The positive coefficient of A and negative coefficient of D in ficient of DE in mathematical equation (i) in section 2.2 (e) con-
mathematical equation (i) in section 2.2 (e) confirms the same. firms the same.

3.5. Interactive effects of NPD & TA on DOP 3.6. Interactive effects of WS & V on HOR

The surface plot in Fig. 8 illustrates the combined effect of NPD The surface plot in Fig. 9 illustrates the combined effect of WS
and TA on DOP. It was inferred from the plot that with increased and V on HOR. It was inferred from the plot that HOR decreases
values of NPD there is a decrease in DOP whereas with higher val- with increasing values of both WS and V. The probable reason
ues of TA there is no significant effect on DOP. As there is a decline which could justify this is with increased V there was more arc

Fig. 4. Interactive effects of WFR & V on WIDTH.

Fig. 5. Interactive effects of WS & WFR on WIDTH.

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R. Narang, V. Maheshwari and P. Khanna Materials Today: Proceedings 44 (2021) 900–908

spread due to which there is decrease in piling of filler metal and
hence results in decrease of HOR. Increased WS also contributes
in decreasing HOR because at higher values of WS less heat per
unit length is introduced in the weld. Hence the graphical study
reveals an overall decline in the curve indicating minimum value
of HOR at maximum values of V & WS.
there is an increase in HOR. Due to the piling effect at higher values
of NPD, HOR increased but a contrast in trend was observed at
higher values of WS. This could be because of less introduction of
heat per unit length results in an overall decrease in HOR. The neg-
ative coefficient of B and positive coefficient of D in mathematical
equation (i) in section 2.2 (e) confirms the same.

3.7. Interactive effects of WS & NPD on HOR
The surface plot in Fig. 10 illustrates the combined effect of WS
and NPD on HOR. It was inferred from the plot that HOR decreases
with increasing values of WS whereas with higher values of NPD
4. Optimization of the welding parameters using response
surface methodology
The major objective of the experimental study was to obtain
optimized welding parameters for achieving the desired weld bead

Fig. 6. Interactive effects of WS & V on WIDTH.

Fig. 7. Interactive effects of WFR & NPD on DOP.

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R. Narang, V. Maheshwari and P. Khanna Materials Today: Proceedings 44 (2021) 900–908

Fig. 8. Interactive effects of NPD & TA on DOP.

Fig. 9. Interactive effects of WS & V on HOR.

geometry. Response surface optimizer feature in the design expert out. This section discusses single and multi-objective optimization
software was employed to desired bead geometry. The process of of welding parameters. The individual solutions thus obtained for
optimization using RSM involves selection of several starting each of the three bead geometry parameters are given in the
points, from where the search for the optimal factor is carried Table 5.

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R. Narang, V. Maheshwari and P. Khanna Materials Today: Proceedings 44 (2021) 900–908

Fig. 10. Interactive effects of WS & NPD on HOR.

Table 5
Single objective optimization results.

Response Parameter Objective Value Optimum welding parameter

A B C D E
Width (W) Maximize 12.85 0.9171 44.05 33.626 10.1325 109.39
Depth of Penetration (DOP) Maximize 6.60 0.6069 44.86 20.646 11.1675 92.72
Height of Reinforcement (HOR) Minimize 0.651 0.3402 49.245 19.752 18.02 75.04

The multi-objective optimization of the process parameters was
also carried and optimized values of A = 1.41 m/min, B = 5.15 cm/
min, C = 21.5 V, D = 10.5 mm, E = 109° were obtained.
5. Conclusions
The following conclusions were found noteworthy on the basis
of investigative work:
(I) In the present study, a five-level, five-factor half- factorial
design matrix based on CCFD was used for the development
of mathematical models to analyze the effect of process
parameters on weld bead geometry and shape relationships
of MIG welded SS409L plates.
(II) The optimum process parameters recommended by the
study are:
a. WFR = 1.41 m/min,
b. WS = 35.15 cm/min,
c. V = 21.5 V,
d. NPD = 10.5 mm
e. TA = 109°
(III) WFR, WS and V were the input parameters which showed
more significant effect on the weld bead characteristics.
(IV) Among the combined effects, the interaction effect of WFR
and V emerged as a dominant influencer for all response
factors.
(V) For bead width, the interaction of WFR and V angle played a
profound role. A maximum width of 13.12 mm was attained
at highest values of WFR and V.
(VI) The peak of penetration 6.95 mm was attained when both V
and WFR were at their peak values.
(VII) The least height of reinforcement observed was 0.66 mm
when NPD and V were both at their peak
CRediT authorship contribution statement
Rishabh Narang: Conceptualization, Validation, Formal analy-
sis, Data curation, Writing - original draft, Visualization. Vibhu
Maheshwari: Methodology, Software, Investigation, Resources,
Writing - original draft. Pradeep Khanna: Writing - review & edit-
ing, Project administration, Supervision.
Declaration of Competing Interest
The authors declare that they have no known competing finan-
cial interests or personal relationships that could have appeared
to influence the work reported in this paper.
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