[Link].

org International Engineering Research Journal (IERJ), Special Issue Page 73-76, 2017 ISSN 2395-1621

ISSN 2395-1621 OPTIMIZATION OF SUBMERGED

ARC WELDING (SAW)
PARAMETERS
#1
Mr. Manjarekar S.S, #2Mr. Gangavane S.A, #3Mr. Kadam R.N,
#4
Mr. Shaikh S.M, #5Mr. Bamankar P.B

#1234
Student Arvind Gavali College of Engineering Satara
#5
Assistant Professor, Arvind Gavali College of Engineering Satara

ABSTRACT ARTICLE INFO

The Welding processes that employ an electric arc is the most prevalent in industry Article History
are Shielded Metal Arc Welding, Gas tungsten Arc Welding, Flux cored arc welding,
Received: 25th March 2017
Gas metal arc welding, Gas submerged arc welding. Welding is a process of joining
different materials. It is more economical and is a much faster process compared to Received in revised form :
both casting and riveting. Submerged Arc Welding (SAW) is one of the oldest
25th March 2017
automatic welding processes provided high quality weld. Submerged Arc Welding
(SAW) uses the arc struck between a continuously fed electrode and the work-piece to Accepted: 25th March 2017
melt the metal in the joint area and provide additional filler metal under a blanket of
granular flux. The Submerged Arc Welding(SAW) is studied copper temperature Published online :
field is gained in this process. In the Submerged Arc Welding is the lot of factors and 4th May 2017
effects affecting on the various metallic material. The thermal effect of Submerged
Arc that specially depends on the electrical arc, flux type and temperature field of it
in work-piece is the main key of analysis and optimization of this process.

Keywords:- RSM, ANOVA, MINITAB, S/N ratio.

I. INTRODUCTION SAW process is suitable for Butt welding and Fillet welding
excessively applications are structure of ships, cladding
Submersible arc welding can be employed for and application. SAW is a generally indoor in fabrication shops.
extremely wide range of work-piece. SAW process is use in SAW process is used widely in the fabrication of pressure
the arc struck between a continuously fed electrode and the vessels, marine vessels, pipelines and offshore structures
work piece to melt the metal in the joint area and provide due to high deposition rate and wide range of work-pieces.
additional filler metal under a blanket of granular flux. This Various optimization methods have emerged to define the
arc is completely submerged under the molten flux, which desired output variables through developing mathematical
protects the molten metal from the atmosphere. There is no models to establish the relationship between the input
visible arc, spatter or fume during the welding operation. parameters and output variables. Observe that the
The electrode of SAW welding is cored wire. It is normally optimization values of welding conditions in spiral pipes
copper coated. and process parameters in hard-facing through submerged
Factors affecting on SAW welding are- arc welding process, Applied Taguchi method to the
Welding current, Welding voltage, Wire diameter, Wire optimization of the submerged arc welding process, Applied
stick out, Flux type, Welding speed, Electrode size, Angle Response Surface Methodology (RSM) for prediction and
of Electrode, Electrode Chemistry, Size, Preheat optimization of weld bead quality in submerged arc welding
temperature, Electrode Protrusion and Worker Skills. of pipes by establishing mathematical models, Analyze the
These parameters have to be selected and precisely effect of microstructure, hardness, and toughness of HSLA
controlled in a judicious manner to achieve weld of desired steel weld joints by varying heat input of submerged arc
quality. Weld quality is depend upon the bead geometry. welding process. Curvilinear equations, linear regression
Increasing travel speed reduces weld penetration but can equations, multiple regression analysis and Taguchi method
cause undercut. Reducing travel speed provides time for the have been used to model SAW process.
gases to escape from the molten metal and thus porosity SAW hard facing process and Taguchi method is widely
may be reduced optimal welding parameters maximum. used for analysis, industry and needs a better prediction and

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 [Link] International Engineering Research Journal (IERJ), Special Issue Page 73-76, 2017 ISSN 2395-1621

monitoring of its parameters. It is necessary to select most this method can be useful for pressure vessel manufacturers
appropriate weld parameter settings to improve weld and operators to search an optimal solution of welding
efficiency, process at low cost and produce high quality condition.
products, But traditional Taguchi method cannot solve Mr. Pradeep Deshmukh [9] et al. studied the various
multi-objective optimization problem effectively. Neural parameters and experiment conducted was using Taguchi’s
networks are considered for modeling the SAW process in orthogonal array L9 method. An experiment was carried out
hard facing. to establish the relationship between process variables and
optimization tools are used to find an optimal solution. A
II. LITERATURE REVIEW confirmation experiment was also conducted and verified
the effectiveness of Taguchi optimization method.
KOZUKI Shohei [1] et al. studied the low heat input S Kumanan[10]et al. studied Multiple regress analysis
welding method is described and utilized. Use of new (MRA) is conducted using statistical package for social
welding technologies such as high energy density beam science (SPSS) software and the mathematical model is
welding by fibre laser welding systems and friction stir built to predict the bead geometry. The experiment was
welding is also expected. Some parameters related to SAW conducted by using the Taguchi’s technique and regression
process were studied that are Increase deposition rate by analysis to determine the optimal process parameters for
smaller diameter welding wire, Increases of penetration SAW process. The proposed mathematical model is used to
depth by smaller diameter wire welding, Effect of smaller predict the SAW process parameters for any given welding
diameter of wire on weld. conditions.
Sahal [2] et al. studied important welding process Dr. P. Ravinder Reddy [11] et al. studied Application of
parameters for multiple performance characteristics weld factorial design approach for optimizing four submerged arc
bead width and bead hardness in the SAW process using welding parameters viz. Arc voltage, welding speed, weld
Taguchi method. A mathematical model was developed and feed speed and nozzle to plate distance. All weld bead
also studied the weld bead geometry and shape relationship parameters increases with an increase in wire feed rate and
in SAW of pipes. decrease with increase in weld speed. The equations
[Link][3]et al. studied the optimization of the developed to predict output parameters when all input
Shielded Metal Arc Welding (SMAW) process parameters parameters lie within limits.
in wind velocity with multi-response criteria using Taguchi Gyanendra Singh [12] et al. studied the important
orthogonal array with grey relational analysis is studied. It parameters in submerged arc welding, Submerged Arc
was found that the optimal welding processes parameters. Welding method. Literature concluded that metal transfer in
Edwin Raja Dhas [4] et al. studied the effects of welding SAW very less work has been reported, which influences
parameters and the optimum welding parameters for a SAW the metallurgy and chemical composition of weld metal.
process on the multiple performance characteristics are Weld bead geometry, arc stability as well as strength of the
systematically investigated by grey relational analysis and weld. The amount of heat generated at work piece and
fuzzy logic with orthogonal array. The optimum procedure welding electrode is effected by polarity change. Thus
of grey-fuzzy logic with orthogonal array, the level influences the metal, weld bead, deposition rate, x, HAZ and
constitution of optimal welding parameters is acquired. mechanical properties of the weld metal.
[Link] [5] et al. studied the characteristics of Arvind Kumar Kachhoriya[13]et al. studied welding is
duplex stainless steel and their properties in welding metal extensively used in fabrications of automobiles, aircrafts,
examined. To determine the behavior of properties and ships, electronic equipment, machinery, and home
transformation, difference in het treatment process and applications etc. as an alternative of casting or as a
systematically investigate the effects of different fluxes replacement of riveted or bolted joints and the study of
were studied. types of wildings
Shashank Soni [6] et al. studied the research explores S Datta[14]et al. studied The study proposes an integrated
practical solutions for welding operations performance optimization approach using Weighted Principal Component
improvement by applying the six sigma [Link] Analysis (WPCA) in combination with Taguchi’s robust
principle provides the metrics required to establish design methodology. Experiments have been conducted
performance improvement goals and a methodology for based on Taguchi’s L25 Orthogonal Array design with
measuring and evaluating improvement. To study a real combinations of process control parameters: voltage, wire
time monitoring system by which the shear strength of the feed, welding speed and electrode stick-out.
weld can be estimated without destructive testing without Aniruddha Ghosh [15] et al. studied detailed information
error and reducing the scrapped cost. on effects of input parameters on weld bead quality
Ankush Batta [7] et al. studied important parameters in parameters and finding out the relationship between them
submerged arc welding, submerged arc welding methods, are very essential for decreasing trial run of SAW process.
wire types and current for welding, wire angle and position: Literature concluded that Condition for optimization of
advantages and drawbacks. submerged arc welding process is maximum penetration,
M. Satheesh[8]et al. studied the high pressure difference minimum reinforcement height, bead width and HAZ width.
across the wall of pressure vessels is potentially dangerous
This paper addresses the application of desirability function III. PROCESS PARAMETERS LEVELS
approach combined with fuzzy logic analysis to optimize
the multiple quality characteristics. For the experiment The process parameters of SAW are welding current,
using Taguchi L27 orthogonal array method. Solutions from voltage, travel speed, wire diameter, electrode stick out, flux,

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 [Link] International Engineering Research Journal (IERJ), Special Issue Page 73-76, 2017 ISSN 2395-1621

heat input, polarity and current type (AC orDC). Welding The S/N ratio takes both the mean and the variability into
current directly influence the depth of penetration and account. The S/N ratio is the ratio ofthe mean (signal) to the
extend of base metal fusion. The welding arc voltage has standard deviation (noise).The standard S/N ratios generally
direct influence on the shape on bead and external used are as follows: nominal-is-best (NB), lower-the-better
appearance of bead. The travel speed has pronounced effect (LB),and higher-the-better (HB). In this paper, the
on weld size and penetration for given combination of characteristic values are selected by the bead width and
current and welding voltage. Careful attention is necessary depth of penetration.
to select the welding process parameters to obtain adesirable S/N ratio and mean values for output responses
weld quality. Though many direct and indirect parameters
affect the quality of weld in SAW the major key process ANOVA (Analysis Of Variance)
parameters affecting the be adgeometry are arc voltage, In statistics, analysis of variance (ANOVA) is a collection
welding current and welding speed. In the present study, of statistical models, and their associated procedures, in
three-levels of which the observed variance is partitioned into components
the three process parameters, i.e., current, voltage and travel due to different explanatory variables. The initial techniques
speed was considered. The values of the welding process of the analysis of variance were developed by the statistician
parameter at different levels are listed in table1 and geneticist R. A. Fisher in the 1920s and 1930s, and are
sometimes known as Fisher's ANOVA or Fisher's analysis
Table1. Process parameters levels of variance, due to the use of Fisher's F-distribution as part
Level Current Voltage Speed of the test of statistical significance By using MINITAB
(Amp) (V) (mm/min) statistical software we are going to optimize the result and
1 300 28 300 results are plotted graphically by using above software.
2 340 32 400 ANOVA for micro- hardness:-The results for micro-
3 380 36 500 hardness are shown in the Table 3. The table consists of the
values of micro-hardness for the nine trials. ANOVA table
Procedure for means is given in following Table. ANOVA table
The experiment was conducted on semiautomatic AUTO indicates that p value for current is having minimum value
WELD MAJOR (LW) with CPRA 800 (S)Power source when micro-hardness is taken as response. P value for
manufactured by Sab India. Mild steel plates of dimensions current is 0.038, which is lesser than 0.05. F value for the
50 mm (length) x 50 mm(width) x 12 mm (height) were current is maximum, which indicates that it is a significant
used as base metal. Auto melts EH 14 copper coated factor contributing to the response, which includes the ranks
electrode of 2.4 mm diameter was used as filler wire. of the contributing factors. In the present study current is the
Agglomerated flux, OK Flux 10.71 (L) Manufactured by most significant factor.
ESAB INDIA Coding - AWS / SFA 5.17 was used. A
square butt joint with a 1.6 mm root opening was selected to IV. CONCLUSION
join the plates in flat position, keeping
electrodeperpendicular to plates. Specimens of 10 mm width Wide research has done on optimization parameters on
were cut transverse to the welding direction from cleaned, submersible arc welding parameters mostly SAW process is
ground, polished and etched with 10% nital (90%alcohol + a submersible welding and various factors affecting that are
10% of nitric acid).Weld bead profiles were traced by using Welding current, Welding voltage, Wire diameter, Wire
an optical microscope at 20Xmagnification. Measurements stick out, Flux type, Welding speed, Electrode size, Angle
were made for depth of penetration and bead width. The of Electrode, Electrode Chemistry, Size, Preheat
observed values of the responses are given in Table.2 temperature, Electrode Protrusion and Worker Skills. Types
of Submerged Arc Welding are as follows Shielded Metal
Table 2. L9 Orthogonal array design and output responses ArcWelding, Gas tungsten Arc Welding, Flux cored arc
welding, Gas metal arc welding, Gas submerged arc
Run Current Voltage Speed Micro-hardness welding.
1 300 28 300 323.11
2 300 32 400 314.66 REFERENCES
3 300 36 500 306.54
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