Optimization of Gas Metal Arc Welding (GMAW) Cladding Parameters for Enhanced Weld Integrity in Low-Carbon Steel Plates (EN30)

Abstract

Weld cladding involves the application of a substantial coating of corrosion-resistant material onto vulnerable substrates with the goal of enhancing their resistance to corrosion. This method provides economic advantages by enabling the utilization of cost-effective and easily workable base materials, which can then be layered with high-quality metals and alloys to attain the desired characteristics in specific parts of the component. Present investigation, gas metal arc welding (GMAW) was utilized to clad low-carbon steel plates (EN30). The cladding parameters considered were voltage (V), wire feed rate (WFR), travel speed (S), and gas flow rate (G). Using a Taguchi L9 orthogonal array, experiments were conducted with three levels for each parameter. ER309L wire with a 1.2-mm diameter and direct current electrode positive polarity were used. A shielding gas of 98% argon and 2% CO2 prevented oxidation during welding. The resulting welds were evaluated by measuring bead profile parameters, including bead width, bead height, depth of penetration, and dilution. Additionally, the weld penetration shape factor (PSF) and weld reinforcement form factor (RFF) were calculated based on these bead profile parameters. Graphical investigation indicated that WFR had the most dominant influence, followed by voltage, on the resultant characteristics. Increasing WFR led to higher welding current, resulting in greater filler material melting per unit length, increased penetration, and higher dilution. To determine the optimal cladding parameters, Taguchi optimization using signal-to-noise (S/N) ratio analysis was employed. The minimum dilution percentage was achieved at WFR1V1G1S1 (WFR = 6 m/min, V = 20 V, G = 16 L/min, S = 240 mm/min). The Taguchi method effectively improved the performance of GMAW cladding for EN30, offering valuable insights for future applications. © 2024 Scrivener Publishing LLC.