Effect of Process Parameters on Angular Distortion

of Stainless Steel 202 Grade Gas Tungsten Arc

Welded Plates

R. Sudhakaran
 Angular Distortion
• Angular distortion is a major problem and most
pronounced among different types of distortion in
the butt welded plates.
• In arc welding processes, due to rapid heating and
cooling the work piece undergoes an uneven
expansion and contraction in all the directions.
This leads to distortion in all the directions of the
work piece.
 To Remove Angular Distortion
• Arrest the work piece in
a base plate
• Pre bend
• Pre strain
 Objectives of the Work
• The extent of angular distortion depend on 1) the
width and depth of the fusion zone relative to plate
thickness, 2) the type of joint 3) the thermo
mechanical properties and 4) the welding process
control parameters

• If an exact magnitude of angular distortion is

predicted, then a weld with no angular distortion
would be the result. It is difficult to obtain analytical
solution to predict angular distortion. Hence various
investigations were made to study the effects of
various parameters on angular distortion using
statistical methods.
 Objectives of the Work
• In the present work, a mathematical model is
developed to establish a relationship between
important process variables namely, welding
current (I), welding speed (V), gas flow rate (Q),
gun angle (θ), plate length (L)

• The design of experiments technique was used to

conduct the experiments. The direct effects of
process variables on angular distortion are studied.
 Experimental Procedure
• These experiments
were conducted using
Lincoln V 350 Pro
Electric Digital
Welding Machine.

• A servo motor driven

manipulator was used
to maintain uniform
welding speed.
 Experimental Procedure
• The welding gun is gun is held
stationary in a frame above the
table and it is provided with an
attachment for setting the
required welding gun angle
respectively.
• Argon is used as the shielding
gas and its flow rate is varied
for each experiment as per the
requirements.
 Plan of Work
Identifying the process variables

Developing the design matrix

Conducting the experiments as per the design matrix

Development of mathematical models

Evaluation of coefficients of the models

Checking adequacy of the models

Testing the regression coefficients of the models

Validation of the mathematical models

Optimizing the results using non traditional optimization techniques

 Limits of Process Variables
Factor Upper Lower
• The angular distortion is a limit limit
function of many
independently controllable Welding 110 70
current (I) amps
process parameters such
as welding current (I), Welding 120 80
welding speed (V), gas speed (V)
mm/min
flow rate (Q), gun angle
(θ), plate length (L) Gas flow rate 25 5
(Q) liter/min
• The design plan was Gun 90 50
decided based on the Angle (θ)
practical considerations Degrees
for the system Plate Length (L) 200 100
mm
 Limits of Process Variables
Process Limits
parameters
-2 -1 0 +1 +2

Welding 70 80 90 100 110

current amps

Welding Speed 80 90 100 110 120

mm/min

Gas flow rate 5 10 15 20 25

Liter/min

Gun angle 50 60 70 80 90
Degrees
Plate Length 100 125 150 175 200
mm
Design Matrix and Recording of Angular
Distortion

• The angular distortion

was measured using
Microscribe G2
coordinate measuring
machine.
 Development of Mathematical
Model
• The experiments were conducted as per the
design matrix at random, to avoid the possibility
of systematic errors infiltrating the system.
• The five process parameters θ, V, Q, L, I are set
as per the design matrix and the experiments are
conducted.
• The mathematical model developed is as below
  3.906  0.388  0.902V  0.968 L 
0.556 2  0.315V 2  0.518 I 2 
0.631( V ) 1.294(  L)  0.746(  I ) 
0.898(V  L) 1.130(V  I ) 1.411(V  Q)
 Validity of The Model

• The validity of the 14

developed model is
12
tested by determining
the error percentage for 10

the observed and 8

Predicted Values
predicted values of

AngularDistortion
Experimental Values
6
effectiveness
• The Fig shows the 4

comparison graph for 2

the experimental and 0

observed values of 1 3 5 7 9 11 13 15 17 19 21 23 25 27

effectiveness. No of Experiments
 Adequacy of The Model
• The adequacy of the model was tested using
the Analysis of Variance Techniques

SS sum of squares, DOF degree of freedom

Mean sum of squares = sum of square terms/DOF
F ratio = MS of lack of fit/ MS of error terms
R ratio = MS of first order term & second order term/ MS of error term
F ratio (6, 5, 0.05) = 4.95
R ratio (20,5, 0.05) = 4.56
 Results and Discussion
• The mathematical model

A ngular Distortion Degrees

8

given above can be used 7

6

to predict the angular 5

4

distortion by substituting 3
2
V = 100 mm/min
L = 150 mm
I = 90 Amps

the values of the values

1 Q = 15 Lit/min
0
50(-2) 60(-1) 70(0) 80(1) 90(2)
of the respective process Gun Angles Degrees

parameters.

A n g u la r D is to r tio n D e g r e e s
5

• The direct effects of the 4.5

4

process parameters on 3.5

3

angular distortion are

2.5 θ =70 °
2 V = 100 mm/min
L = 150 mm
1.5

discussed below.
Q = 15 Lit/min
1
0.5
0
80(-2) 90(-1) 100(0) 110(1) 120(2)
Welding Speed mm/min
 Results and Discussion
7
A ngula r D is tor tion D e gr e e s

4.5

A ngula r D is tortion D e gre e s

6 4

5 3.5
3
4
2.5
θ = 70°
3 2
θ = 70° V = 100 mm/min
V = 100 mm/min 1.5 L = 150 mm
2
I = 90 Amps 1 I = 90 Amps
Q = 15 Lit/min
1 0.5

0 0
100(-2) 125(-1) 150(0) 175(1) 200(2) 5(-2) 10(-1) 15(0) 20(1) 25(2)
Plate Length mm Gas Flow Rate Litre/Min
A n g u la r D is to r tio n D e g r e e s

3 θ = 70°
V = 100 mm/min
2 L = 150 mm
Q = 15 Lit/min
1

0
70(-2) 80(-1) 90(0) 100(1) 110(2)
Welding Current Amps
 Conclusions
• The second order quadratic model can be
effectively used to predict angular distortion in
gas tungsten arc welding of stainless steel 202
grade plates.

• Central composite design can be conveniently

used to predict the direct effects of different
combinations of process parameters within the
range of investigation on the angular distortion
of gas tungsten arc welded stainless steel 202
plates.
 Conclusions
• The predicted angular distortion is compared
with the experimental one and the deviations
falls within the limit of 95% confidence level.
• The maximum angular distortion is 12° when all
the process parameters are maintained at -1
level and welding speed is maintained at +1 level.
• Out of the five process parameters selected for
investigation, welding current has strong effect
on angular distortion; plate length has a
negative effect on angular distortion where as
gas flow rate has no significant effect on angular
distortion.
THANK YOU