Effects of Process Parameters on Weld Bead Penetration in SAW

A two-Level half fractional design is used to investigate and quantify the direct and interaction effects of four process parameters on weld bead penetration in SAW of mild steel.

Wire feed rate, open circuit voltage, welding speed and plate thickness were taken as the welding parameters to investigate the main and interaction effect on the weld bead penetration. The analysis indicated that of the four parameters investigated, only wire feed rate had the statistically significant main effect on weld penetration. It was also observed that wire feed rate & welding speed and open circuit voltage & plate thickness interact to affect the weld penetration. A model has been proposed for predicting the weld penetration. The adequacy of the model was tested by the use of analysis of variance technique and the significance of the coefficients was tested by the student’s ‘t’ test. The estimated and observed values of the bead penetration have been compared in a scatter diagram. The main and interaction effects of different parameters involved have been presented in graphical form.