Mathematical Modeling of Shape relationship including % Dilution and Total Bead Volume in SAW Process by using Two Level Half Factorial Technique

The fabrication industry extensively uses SAW (Submerged Arc Welding) owing to its quality, precision and high production rate. The quality and strength of the weld are controlled by the weld bead geometry criterion and shape relationship, which are greatly influenced by the SAW process control variables, namely welding current, arc voltage, welding speed and nozzle-to-plate distance. The present study aims to develop mathematical relations between weld penetration shape factor (WPSF), weld reinforcement form factor (WRFF), % dilution, and total volume with process control variables. Experiments were conducted using “Two Level Half Factorial Design Techniques”. Design Expert software was deployed for graph plotting for the primary and interaction effects of process control variables on bead geometry parameters. Results indicated that voltage affects WPSF positively, while welding current and nozzle-to-plate distance affect WPSF negatively, and welding speed has an insignificant effect on WPSF. Similarly, for WRFF, arc voltage and welding speed have a positive effect, while welding current and nozzle-to-plate distance have a negative impact. For % dilution, nozzle-to-plate distance has an adverse effect and welding current has an insignificant impact. Welding current effects, the total bead volume, arc voltage, welding speed, and nozzle-to-plate distance have adverse effects.