STUDY ON THE WELDMENT CHARACTERISTICS OF CARBON

STEEL PLATE WELDED BY GMAW USING DIFFERENT

CURRENT VALUES

SHAFIQ BIN BRAHIM @ IBRAHIM

50249210477

BACHELOR OF ENGINEERING TECHNOLOGY

(WELDING QUALITY AND INSPECTON)

UNIVERSITY KUALA LUMPUR

SEPTEMBER 2013
 UNIVERSITI KUALA LUMPUR
MALAYSIA FRANCE INSTITUTE
FINAL YEAR PROJECT (FYP) REPORT
SUBMISSION REPORT

PROJECT TITLE

STUDY ON THE WELDMENT CHARACTERISTICS OF

CARBON STEEL PLATE WELDED BY GMAW USING
DIFFERENT CURRENT VALUES.

RECEIVER’S STAMP AND SIGNATURE

SEMESTER 7 SESSION SEPT 2013

PROGRAM Bachelor Of Engineering Technology (Hons.)

in Welding Quality Inspection
SUBMISSION
DATE
SUPERVISORS 1. MR. ABDUL RAHIM BIN OMAR
STUDENT NAME STUDENT ID.
NAME
SHAFIQ BIN BRAHIM
& 50249210477
@IBRAHIM
ID
SUBMISSION DATE:
REPORT TITTLE:
STUDY ON THE WELDMENT CHARACTERISTICS OF
CARBON STEEL PLATE WELDED BY GMAW USING
DIFFERENT CURRENT VALUES.

SHAFIQ BIN BRAHIM @IBRAHIM

50249210477

Report Submitted to Fulfill the Partial Requirements for the

Bachelor of Engineering Technology (Welding and Quality
Inspection)

UNIVERSITY KUALA LUMPUR

SEPTEMBER 2013

i
 APPROVAL PAGE

I/We have examined this report and verify that it meets the program and
University’s requirements for the Bachelor of Engineering Technology in Welding
Quality and Inspection.

Date: _______ / ___ / ________ Signature:

Supervisor’s Name;

Official Stamp:

Date: _______ / ___ / ________ Signature:

Co-Supervisor’s Name;

Official Stamp:

ii
 DECLARATION

I declare that this report is my/our original work and all references have been
cited adequately as required by the University.

Date: _______ / ___ / ________ Signature:

Full Name;

ID No:

iii
 DEDICATION

To my enduring and supportive supervisor, Mr. Abdul Rahim bin Omar and

Last but not least, my classmates and housemates,

For everlasting love and support through happiness and hardships.

Thank you for the morale support and inspiration.

iv
 ACKNOWLEDGEMENT

In the name of Allah S.W.T, the Beneficent, the Merciful and all praises to
Him for through His guidance and perseverance granted by Him that I would be able
to complete my final year project.

First of all I would like to seize this opportunity to express my highest

gratitude towards my supervisor Mr. Abdul Rahim bin Omar in sharing his
knowledge and guidance with me in every step that I took. Without him it would be
impossible for me to fully finish my project on “Study on the Weldment
Characteristics of Carbon Steel Plates welded by GMAW using difeerent Current
values.’’

I am also deeply grateful to MFI for providing very excellent work and study
condition, suitable with UniKL motto, “Where Knowledge is Applied”.

My special thanks and love to my parents, brother and classmates for the
continuous support through thick and thin.

Thank you all.

v
 ABSTRACT

The purpose of this study is to identify the relationship between the current
value of the Gas Metal Arc Welding (GMAW) process, and the characteristics of the
weldment produced on the carbon steel plate. The characteristics that will be
observed are the depth of the weld penetration and the rate of weld formation. The
variable in this study is the current value of the GMAW process. This study uses
carbon steel plates of thickness 9mm. The current value of the GMAW process will
be increased gradually. Each of the carbon steel plate of different current will be
welded to form horizontal weld bead. All the welding will be done in 1G (horizontal)
position. This study will determine the best current parameter in welding 9mm
carbon steel plates.

vi
 TABLE OF CONTENTS

LIST OF CONTENT PAGE

TITLE PAGE i

APPROVAL PAGE ..................................................................................................... ii

DECLARATION ........................................................................................................ iii
DEDICATION ............................................................................................................ iv
ACKNOWLEDGEMENT ........................................................................................... v
ABSTRACT ................................................................................................................ vi
TABLE OF CONTENT vii-ix

LIST OF FIGURES ..................................................................................................... x

LIST OF TABLES ...................................................................................................... xi

CHAPTER 1
INTRODUCTION ....................................................................................................... 1
1.1 Gas Metal Arc Welding ................................................................................................. 1
1.2 Problem Statement ......................................................................................................... 2
1.3 Objective ........................................................................................................................ 2
1.4 Scope of study ................................................................................................................ 2
1.5 Classification of welding process .................................................................................. 3
1.6 Description of GMAW .................................................................................................. 4
1.7 Possible Defects ............................................................................................................. 5
1.8 GMAW Process Parameters........................................................................................... 5
1.9 Description of A36 Low Carbon Steel ........................................................................... 6
1.10 Applications of A36 Low Carbon Steel ....................................................................... 6

CHAPTER 2
LITERATURE REVIEW............................................................................................. 7
2.1 Types of Metal Tested 7

2.2 Welding Current 8

2.3 GMAW Machine 9

vii
 2.4 Filler Wire 10

CHAPTER 3
METHODOLOGY ..................................................................................................... 12
3.1 Material Used in the experiments ................................................................................ 13
3.1.1Various Types of Carbon Steel .................................................................................. 13
3.1.2 Effect of alloying Elements on Steel......................................................................... 13
3.1.3 Specimen Size Specification ..................................................................................... 14
3.2 GMAW Machine ......................................................................................................... 15
3.3 GMAW Welding Parameters ....................................................................................... 16
3.4 Radiographic Testing ................................................................................................... 16
3.5 Metallographic Examination ........................................................................................ 17
3.8 Macro Etching Examination ........................................................................................ 18

CHAPTER 4
RESULTS AND DISCUSSION ................................................................................ 19
4.1 Quality of Weld............................................................................................................ 19
4.1.1 Selecting the best specimen by using Visual Inspection ....................................... 19
4.2 Radiography Inspection ............................................................................................... 20
4.3 Macro Etching Examination Results............................................................................ 21
4.4 Metallographic Examination Results ........................................................................... 23

viii
CHAPTER 5
CONCLUSION .......................................................................................................... 25
5.1 Results from tests ......................................................................................................... 25

CHAPTER 6
RECOMMENDATION ............................................................................................. 26
6.1 Recommendations for further research ........................................................................ 26

REFERENCES
References 27

APPENDICES

ix
 LIST OF FIGURES

FIGURE NO. TITLE PAGE

Figure1.1 Classification of Welding ........................................................................................ 3

Figure1.2 GMAW process by Paul F. MacHale (December 1991) ......................................... 4

Figure3.1 Flow chart of the investigation and activities ........................................................ 12

Figure3.2 GMAW Machine ................................................................................................... 15
Figure3.3 Example of Micrography ....................................................................................... 17
Figure3.4 Macro Etching Coupon.......................................................................................... 18

Figure4.1 Radiograph film ..................................................................................................... 20

Figure4.2 Macro Etch 100A....................................................... Error! Bookmark not defined.
Figure4.3 Macro Etch 120A....................................................... Error! Bookmark not defined.
Figure4.4 Macro Etch 140A................................................................................................... 15
Figure4.5 Macro Etch 160A....................................................... Error! Bookmark not defined.
Figure4.6 Micrography 100A ................................................................................................ 23
Figure4.7 Micrography 120A ................................................................................................ 23
Figure4.7 Micrography 140A ................................................................................................ 24
Figure4.7 Micrography 160A ................................................................................................ 24

x
 LIST OF TABLES

TABLE NO. TITLE PAGE

Table1. 1 Oxidation Potential of Commonly used Shielding Gas _____________________ 5

Table1.2 Chemical composition, ASTM A36 : Standard Specification for Carbon Structural
Steel 6

Table3.1 Steel types categorized by carbon content ______________________________ 13

Table3.2 Specimen size off A36 _____________________________________________ 14
Table3.3 Welding Parameters _______________________________________________ 16

Table4.1 Radiography Inspection Result _______________________________________ 20

Table4.2 Relationship between Current Value and Depth of weld Penetration__________ 22

xi
 CHAPTER 1

INTRODUCTION

1.1 Gas Metal Arc Welding

Gas Metal Arc welding is an arc welding process that uses an arc between a
continuously-fed filler metal electrode and the weld pool. The process is used with
shielding from an externally supplied gas and without the application of a pressure. It
is also known as MIG welding or MAG welding where MIG (Metal Inert Gas)
welding refers to the use of an inert gas while MAG (Metal Active Gas) welding
involves the use of an active gas (i.e. carbon dioxide and oxygen).

Metal inert gas welding is the most economic process for metal thicker than 6
mm diameter. Control of penetration is difficult for thin gauge material. In the metal
inert gas process a direct current (D.C.) arc of reverse polarity is struck between the
work piece and a continuously fed aluminium wire which acts as both the filler and
the electrode. Fluxes are unnecessary. The arc itself cleans the electrode and welds
pool, whilst re-oxidation is prevented by a shield of inert gas which envelopes the
area. Since the electrode is continuous, welding speeds are high with small arc size.
Owing to the higher average rate at which welds can be completed, it is well suitable
for the welding of aluminium.

Carbon steels are defined as the steels that contain up to 2% C, 1.65% Mn,
0.60% Si, and 0.60% Cu with no other addition of other elements. The term "carbon
steel" may also be used in reference to steel which is not stainless steel; in this use
carbon steel may include alloy steels. As the carbon percentage content rises, steel
has the ability to become harder and stronger through heat treating. Weldability of
carbon steels greatly depend on the content of carbon and manganese and the
impurity level.

1
1.2 Problem Statement

In order to fully understand how current value of GMAW process affects the quality
of weldments, we need to know what effects does the current value has. To achieve
this, it is imperative that an investigation pertaining to the objectives of the case
study to be done. By looking at the microstructure and the measurement done in
macro etching test, we can determine the effects current value have on weldment,
carbon steel weldments specifically.

1.3 Objective

 To investigate the effects of GMAW current values on welding 9mm carbon

steel plate.
 To inspect the microstructures of the carbon steel plates that were welded
using different values of current..

1.4 Scope of study

 To perform butt joint using GMAW process on A36 9mm thick carbon steel.
 To perform metallogrpahic testing to identify grain microstructures.
 To perform macrostructure examination to check weld penetration level.

2
1.5 Classification of welding process

Figure1.1 Classification of Welding

Gas Metal Arc Welding

Most applications of gas metal arc welding use a constant voltage power
supply. Any change in arc length results in a large change in heat input and current.
It is used extensively by the sheet metal industry and, by extension, the automobile
industry.

3
1.6 Description of Gas Metal Arc Welding (GMAW)

Gas Metal Arc Welding (GMAW) also known as Metal Inert Gas (MIG) welding
produces a weld by heating metals with an arc established between a consumable
electrode (continuously fed) and the base metal. A shielding gas protects the weld
metal but this welding process is not as clean as Gas Tungsten Arc Welding
(GTAW) process. The consumable electrode produces a less stable arc and the larger
arc lengths associated with GMAW may adversely affect the performance of the
shielding gases.

Direct current reverse polarity (DCRP) is used in GMAW to produce a stable

arc, smooth metal transfer and sufficient weld penetration. There are three basic
modes of metal transfer in GMAW. First is short-circuiting in which the filler metal
is transferred to the weld pool. The second one, globular metal transfer, in which the
metal drops to the weld pool under the gravitational force. And lastly, spray, attracts
the metal drops to the weld pool under the influence of electromagnetic forces.

Figure1.2 GMAW process by Paul F. MacHale (December 1991)

4
 98% Argon 75% Argon 85% Argon
2% O2 (O-2) 25% CO2 (C-25) 15% CO2 (C-15)
Degree of oxidizing Slightly oxidizing More oxidizing More oxidizing

Table 1.1 Oxidation Potential of Commonly used Shielding Gas

As for the shielding gases, there are 3 most commonly used in welding mild and low
alloy steels and are classified according to their oxidizing effect as shown in Table
1.1.

In the industry production environment, C-15 shielding gas is the most

commonly used for welding carbon and low alloy steels. Meanwhile, for small scale
production and hobbyists, C-25 is their choice for welding of carbon steels. O-2
shielding gas probably gives the highest quality weld, but is very expensive due to
the high percentage of Argon.

1.7 Possible Defects

 Lack of penetration.
 Undercut.
 Burn-through.
 Porosity.
 Cracking.

1.8 GMAW process parameters

The process parameters for GMAW are current (amperage), voltage, types of
shielding gases, types of filler metal and wire thickness.

5
1.9 Description of A36 Low Carbon Steel

A36 is the most commonly used mild and hot-rolled steel. It has excellent welding
properties and is suitable for grinding, punching, tapping, drilling and machining
processes.

Table 1.2 Chemical composition, ASTM A36 : Standard Specification for Carbon
Structural Steel

1.10 Applications of A36 Low Carbon Steel

 Bolted, riveted or welded construction of bridges, buildings and oil rigs.

 .Automotive, agricultural equipments, machinery, and various basic

structure parts.

 Used for various parts obtained by flame cutting such as in parking garages,
walkways, boat landing ramps and trenches.

6
 CHAPTER 2

LITERATURE REVIEW

2.1 Types of metal tested

The type of metal tested is one of the most crucial part in the investigation to
determine the effects of current on the weldment characteristics. It plays a critical
role in material flow, ease of weld penetration, and the microstructure of the
weldment. There are usually several types of metal and metal alloys iteration used in
the industry today. The most common ones are carbon steel (and its iterations),
aluminium, and cast iron. Each of these materials has different mechanical properties
and each has at least one purpose in which it will excel over the other materials.

Mild carbon steel, also known as low carbon steel is the most common form
of steel used in the industry and it provides material properties that are acceptable for
many applications. It is malleable and ductile, its surface hardness can also be
increased via carburizing. Low carbon steels contain less carbon than other steels and
are easier to cold-form, making them easier to handle.

Zhang, W. et al (2003) made a modeling of heat transfer during spot welding

of low carbon steel. It is found that low carbon steel’s weld pool solidifies with
decreasing interface stability, i.e., with higher tendency to form dendrites toward the
center of the weld pool.

Quinn, T.P. (2002) states that aluminium is more sensitive to changes in

current compared to low carbon steel. This is due to aluminium having higher
thermal conductivity, lower electrical resistance, and lower melting point.
Conductive heat transfer is more important in aluminium. In carbon steel, resistive
heating, phase change, and convection are relatively more important.

7
 Oladele Isiaka Oluwole et al (2010) uses aluminium instead of carbon steel in
their research to study the effects of welding current and voltage on the mechanical
properties of wrought (6063) aluminium alloy. They found that in aluminium, current
values affect the ultimate tensile strength and hardness of the welded specimen .

2.2 Welding Current

As this study involves using welding current as the variable, it is important to

look at the effects welding current has on other types of metal or whether does it
affect other parameters involved during welding.

Oladele Isiaka Oluwole et al (2010) used current values of 75A and 100A in
their research to study the effects of welding current and voltage on the mechanical
properties of wrought (6063) aluminium alloy. It was found that 100A current gives
better ultimate tensile strength and hardness compared to 75A current. This may hold
some relevance when studying current effects on welding low carbon steel.

Weglowski et al (2008) studied the effect of welding current on metal transfer

in GMAW. In their study, current values above approximately 215A will have
distinctly increased metal transfer rate, while current values below 180A have
distinctly lower metal transfer rate and the differences are not as significant.

Aslanlar, S., et al (2007) studied the effect of welding current on the quality
of weld joint and obviously on tensile-shear and tensile-peel strengths of galvanized
chromate steel sheets having 1.2 mm thickness in electrical resistance spot welding
was investigated. A timer and current controlled electrical resistance spot welding
machine having 120 kVA capacity and pneumatic application mechanism with a
single lever was used to prepare the specimens. Welding periods were chosen as 5,

8
10, 12 and 15 cycles and also welding currents were increased from 4 kA up to 12
kA by rise of 1 kA.

Karadeniz et al (2007) investigated 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. The welding current, arc voltage and welding speed
were chosen as variable 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 95A, 105A, and
115A.

2.3 GMAW Process

This investigation uses Gas Metal Arc Welding as the welding process of
choice. GMAW process usually perform using Direct Current Electrode Positive
(DCEP). Alternating Current is never used on GMAW. Direct Current Electrode
Negative (DCEN) is used only for specialized process using emissive electrodes.

Talkington, John Eric (1998) did a study on the effects of percentage of

DCEN versus DCEP current on bead characteristics and arc stability. He performed
bead-on-plate tests on mild steel plate using 0.045 inch diameter ER70S-6 wire. The
percentage of DCEN current versus DCEP current was found to have significant
affects on penetration, power, and arc stability. It was found that penetration and
welding power are reduced with higher percentages of DCEN current while arc
stability problems were increased with higher percentages of DCEN.

Y-S Kim et al (1993) did an analysis of metal transfer in GMAW. The

welding equipment used included a constant surrent power supply, and a voltage
controlled electrode feed with a “low-inertia” motor. He analyzed the metal transfer
of the GMAW process using high-speed videography with a laser back-lighted

9
shadowgraphic method. In this study, he found that the transition of metal transfer
mode in GMAW occurs much more gradually than is generally believed.

Zhang, W. Et al (2004) did an investigation on heat and fluid flow in complex

joints during gas metal arc welding; application to fillet welding of mild steel. They
used dimensional analysis to understand the importance of heat transfer by
conduction and convection and the role of various driving forces on convection in the
liquid weld pool. The calculated shape and size, finger penetration characteristic and
solidified surface profile of the fillet welds were in fair agreement with the
experimental results for various welding conditions.

2.4 Filler Wire

Filler wire is an important part in most arc welding processes. Although some
arc welding process does not use filler wire, the filler metal electrode’s function is
basically the same. Types of filler wire affects the weldment overall properties, and
thus it is usually with great deliberation in the process of choosing the most suitable
filler wire.

Wifnerell, Charles E. (1963) patented a consumable welding wire for use in

shielded arc welding that will lay down a nickel-chromium alloy weld deposit and
over lay that is substantially free from cracks and porosity while also possesing good
arc characteristics. His invention was by employing a nickel-chromium alloy filler
wire of unique composition.

Tenkula, Jaakko et al (1984) invented the then new filler wire for use in arc
spraying. The basic idea of the invention is that in arc spraying a totally new type of
filler wire is used which can be alloyed in the desired manner in order to produce
resistance to mechanical and chemical wear. The filler wire comprises a sheath made

10
of soft unalloyed or alloyed metal and a core consisting of metal powder or of a
mixture of a metal powder and special carbides and oxides.

11
 CHAPTER 3

METHODOLOGY

The experiments were conducted using Gas Metal Arc Welding (GMAW) on
commercial A36 Carbon Steel plate. Flow chart of experimental activities is
described in Figure 3.1.

Procurement of
materials,
parameter
deliberation

Welding process
and
establishment
parameter
process

Radiography, Micro
and Macro-Etch
Examination

Conclusion and

Recommendation

Figure3.1 Flow chart of the investigation

12
3.1 Material Used in the experiments
The experiments were conducted on A36 mild/low carbon steel. This
particular type of carbon steel contains less than 0.3% carbon in its composition. It is
alloyed with magnesium and very small amount of sulfur, to improve hardenability
and to make the carbon steel malleable and plastic at high temperature .

3.1.1 Various Types of Carbon Steels

Considering there are several classifications of carbon steel, it is imperative to
identify them based on their carbon content percentage.

Type Carbon Content

Low Carbon Steel <0.3%
Medium Carbon Steel 0.30-0.59%
High Carbon Steel 0.60-0.99%
Ultra-High Carbon Steel 1.0-2.0%
Table3.1 Steel types categorized by carbon content
Low and Mild carbon steel

Mild steel, or plain-carbon steel is the most common form of steel because its
price is relatively low while it provides material properties that are acceptable for
many applications, more so than any other metals. Low carbon steel contains about
0.05% to 0.3% carbon content making it ductile and malleable. Low carbon steel is
often used when large quantities of steel are needed, such as for making bridges and
other structures.

3.1.2 Effects common alloying elements in Steel

Carbon

The basic metal, iron, is alloyed with carbon to make steel and has the effect of
increasing the hardness and strength by heat treatment but the addition of carbon
enables a wide range of hardness and strength.

13
Manganese

Manganese is added to steel to improve hot working properties and increase strength,
toughness and hardenability. Manganese, like nickel, is an austenite forming
element.

Chromium

Chromium is added to the steel to increase resistance to oxidation. This resistance

increases as more chromium is added. 'Stainless Steel' has approximately 11%
chromium and a very marked degree of general corrosion resistance.

Sulphur

When added in small amounts sulphur improves machinability but does not cause hot
shortness. Hot shortness is reduced by the addition of manganese, which combines
with the sulphur to form manganese sulphide.

Silicon

Silicon is used as a deoxidising (killing) agent in the melting of steel, as a result,

most steels contain a small percentage of silicon. Silicon contributes to hardening of
the ferritic phase in steels.

Nickel

Nickel is added in large amounts, over about 8%, to high chromium stainless steel to
form the most important class of corrosion and heat resistant steels.

3.1.3 Specimen Size specification.

The base material is cut to the size as given in Table 3.2. The materials are
cut according to this size for the convenience of the welder.

Length 150mm
Width 80mm
Thickness 9mm
Table3.2 Specimen size off A36

14
3.2 GMAW machine

The welding experiments were carried out with a GMAW machine with these
specifications:

 Input supply : 415 +/- 10 % Variation, 3 Phase 50 H +/-

 Type of cooling : Forced air-cooled
 No load power consumption : <75W
 Shielding medium : Argon + Carbon Dioxide gas mixture

Figure 3.2 GMAW machine

15
3.3 Gas Metal Arc Welding Process Parameter

To get the best welding process parameter I utilized trial and error method in
deliberating the welding parameters. Trial and error is a fundamental method in
determining the parameters. It is characterized by repeated, varied attempts which are
continued until success or until the agent stops trying. In this study, voltage,
shielding gas, and the filler metal are constant while current (amperage) is varied.
The welding parameters are given in table 3.3.

Force Constant
Voltage (V) 20
Shielding Gas C-15
Table3.3 Welding Parameters

3.4 Radiography Test

Radiographic Testing (RT) is a nondestructive testing (NDT) method of
inspecting materials for hidden flaws by using the ability of short wavelength
electromagnetic radiation to penetrate various materials. Radiographic testing can
provide a permanent film record of weld quality that is relatively easy to interpret by
trained personnel. Although this is a slow and expensive method of nondestructive
testing, it is a positive method for detecting porosity, inclusions, cracks, and voids in
the interior of welds.

16
3.5 Metallographic Testing

Metallography is the study of the physical structure and components of

metals, typically using microscopy. Ceramic and polymeric materials may also be
prepared using metallographic techniques, hence the terms ceramography,
plastography and, collectively, materialography.

Figure3.3 Example of micrography

17
3.6 Macro Etching Examination Test

Macro etch testing allows the tester to see a cross section of the weld, and see
the arrangement of the grains in the parent metal and the weld material. It can also
show up penetration level and defects such as porosity, inclusions and poor fusion.
Figure 3.7 show the macro etching testing coupon.

Figure3.4 Macro Etching Coupon

18
 CHAPTER 4

RESULTS AND DISCUSSION

4.1 Quality of Weld

4.1.1Selecting the best specimen by using Visual Inspection

By using visual inspection, all 4 of the specimens are checked for any visible
defects. For the 100A specimen, the weld is clearly underwhelming due to the spatter
caused by insufficient current. For 120A and 140A, they share the same weld
characteristics with decent weld line and no visible discontinuity. Lastly, for the
160A, it shows the smoothest and most visually impressive weldment out of all the
specimens.

19
4.2 Radiography Inspection
X‐Ray radiographic inspection was carried out and the radiograph test result
indicated that there is a lack of penetration and the acceptance criteria (stringent) as
per ISO5817 is classified as rejected. The result as shown in the radiographic film is
shown in Figure 4.4 and results are given in Table 4.4.

Figure4.1 Example of lack of penetration in radiograph film

Result as
per
Weld Reinforcement Material Film
ISO5817
Current thickness thickness thickness interpretation
Acceptanc
e Criteria

Lack of
100 12 3 9 Rejected
Penetration
Lack of
120 12 3 9 Rejected
Penetration
Lack of
140 12 3 9 Rejected
Penetration
Lack of
160 12 3 9 Rejected
Penetration

Table 4.1 Radiography Inspection Result

20
4.3 Macro Etching Examination Results

The exposed of the weld cross sections indicated incomplete root fusion at the
weldment zone and have some minor defects and is found to be unsatisfactory. The
photographs of tested specimens are shown in Figure 4.2 to 4.5. The level of
penetration level measured are approximately 2.5, 3.0, 3.5, and 4.0 mm respectively.

2.5mm
m

Figure 4.2 Macro Etch 100A

3.0mm

Figure 4.3 Macro Etch 120A

21
 3.5mm
m

Figure 4.4 Macro Etch 140A

4.0mm

Figure 4.5 Macro Etch 160A

Table 4.2 Relationship between Current Value and Depth of weld Penetration

22
4.4 Metallographic Examination Results

Metallographic examinations were carried out on all of the 4 specimens. The

weld zones of the specimens are prioritized and 50 times magnification was chosen.
The micrographs show the melting reaction of filler metal particles with the base
metal matrix. In Figure 4.7 and 4.8 the grain structures are show particularly fine
grain structure. This indicates good weld quality and it should have good mechanical
properties. In Figure 4.5 and 4.6, the grain structures are less fine and this indicate
lack of weld quality and less-than-desirable mechanical properties.

Figure 4.6 Micrography 100A

Figure 4.7 Micrography 120A

23
Figure 4.8 Micrography 140A

Figure 4.9 Micrography 160A

24
 CHAPTER 5

CONCLUSION

5.1 Results from tests

From the results of all the tests and examinations done on the 4 specimens, it
can be concluded that both 140A and 160A made better weldment compared to 100A
and 120A. However, all of the current value specimens failed to achieve complete
penetration. To compensate for this inadequacy, welders can modify the butt joint to
be any of these; single-V, double-V, single bevel, double bevel, single-J, double-J
single-U, and double-U. They can also weld on both surface of the butt joint.

The lower current value of the specimens perform rather poorly largely due to
the material properties of low carbon steel. If this study was done using aluminium, it
stands to reason that both 100A and 120A will produce sound welds. Despite the
results, A36 low carbon steel plate 9mm thick is weldable using all of the current
values, weld quality set aside. Although for future reference and to increase the
overall quality of future welds it is necessary to look into various factors seriously
especially in achieving a good level of root fusion and penetration. The factors are
mentioned in Chapter 6 under suggestions and recommendations.

25
 CHAPTER 6

RECOMMENDATION

6.1 Recommendations for further research

Gas Metal Arc Welding is the most used welding process in the world and
carbon steel is the most commonly used material in structural buildings and other
metal industries. In order to increase productivity and reduce economic loss by
defective welds, it is highly recommended that the most optimal parameters are used
when welding.

The followings are suggested and recommended:-

 An increase in the welding current values in accordance to the thickness and

the type of the base metal.;
 The welding of two dissimilar materials while holding the welding
parameters as the variable is also an area of interest that can be looked into in
the future;
 Further studies regarding my investigation can also be done but using a wider
range of values before embarking into heavier materials;
 Further mechanical and metallurgical tests could be performed such as in the
fatigue failure analysis and shear tests in the future.

26
 REFERENCES

1. R.W. Messler, Principles of Welding, Processes, Physics, Chemistry,

Meallurgy, Chapter 3, John Wiley and Sons, New York, 1999.
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8. Karadeniz, Erdal, Ugur Ozsarac, and Ceyhan Yildiz. "The effect of process
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APPENDICES

28
Appendix 1 (Micrography Images)

Base Metal 100A 50x magnification

Base Metal 120A 50x magnification

29
Base Metal 140A 50x magnification

Base Metal 160A 50x magnification

30
HAZ 100A 50x magnification

HAZ 120A 50x magnification

31
HAZ 140A 50x magnification

HAZ 160A 50x magnification

32