Welding Lab Data and Report (Week 2/2): Weld Process Control

Control of arc welding variables is key to producing high quality welds of proper size and shape. In this task,
we will investigate the effects of flux-cored arc welding (FCAW) variable for making ‘bead-on-plate” welds on
AISI 1020 steel.

An automatic torch travel welding device to allow us to control the variables that we want to analyze
by removing human variability from manual FCAW. The device is set up with Flux-Core wire that is
also aided by inert gas (75% Argon and 25% Carbon Dioxide). A total of 16 weld were made using the
following welding conditions:

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For each welding condition the welding heat input (kJ/in) can be calculated

Each weld was cross sectioned, ground, polished and etched to reveal the cross-sectional geometry of
the weld beads. This includes the overall height and width of the weld bead as well as the depth of
penetration into the metal and the amount of reinforcement above the surface of the welded plate.

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Data

The resultant weld geometry data for each weld is indicated here. Units are in inches.

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 Weld Images

Report (2 pages text, single-spaced + figures and tables)

The FCAW welding guide posted on CANVAS is a useful guide for understanding the influence of
welding conditions on weld bead geometry. Refer to it for assistance in completing your report.

What is the influence of individual welding variables and heat input (a combined variable) on the
various aspects of weld bead geometry. (Data plots and statistical analysis are needed.) Which
variables have the most dominant effects on the various aspects of weld bead geometry?

Do the results of your experiment agree with the literature? Discuss.

Problem solving: Write a 2-paragraph description that would be part of a training guide for new
welders that describes what FCAW welders should do to maintain adequate weld penetration during
manual welding. Make sure that you include discussion of other significant welding variables that may
have been held constant in the lab data that you analyzed.