The Influence of Process Parameters on Weld Droplet Diameter in MIG Welding: An Experimental Study

Metal Inert Gas (MIG) welding is a widely utilized welding process due to its efficiency and versatility. The weld droplet diameter is a critical parameter that significantly influences weld quality, including bead geometry, penetration, and mechanical properties. This study investigates the effects of welding current, voltage, and wire feed rate on the weld droplet diameter using locally sourced materials. A design of experiments (DOE) approach was employed, with parent samples measuring 40mm × 40mm × 10mm. Twenty experimental runs were conducted, and the results were analyzed using ANOVA. The findings reveal that voltage and current have a significant impact on the droplet diameter, while the wire feed rate exhibits negligible influence. A mathematical model was developed to predict the droplet diameter, and optimization was performed to identify the optimal process parameters. The model demonstrated a high R² value of 0.9008, indicating a strong correlation between the predicted and experimental results. The optimal parameters for achieving a droplet diameter of 1.024mm were identified as a current of 240A, a voltage of 24.168V, and a wire feed rate of 3.0mm/s. This study provides valuable insights into the relationship between process parameters and droplet diameter, offering a framework for optimizing MIG welding to enhance weld quality.