Process optimization of double-pulsed GMAW using the Taguchi method for enhanced tensile strength

• Low-carbon steel plates were successfully welded using the DP-GMAW technique. • Tests were conducted on two specimen groups: smooth and reinforcement. Reinforcement specimens exhibited up to 15 % higher tensile strength. • The parameters wire feed speed, pulse current, and frequency were optimized using the Taguchi method. • For the smooth specimens, the optimal parameters were 6.0 m/min wire feed speed, -3 % pulse current, and 3 Hz frequency, while for the reinforcement specimens they were 6.8 m/min, −3 %, and 1 Hz. • Wire feed speed had the highest effect on tensile strength, with contribution ratios of 90.85 % for smooth and 91.73 % for reinforcement specimens. • Verification tests confirmed the effectiveness of the optimization, indicating that the Taguchi method improves efficiency by reducing time and resource usage in the DP-GMAW process. Double pulsed gas metal arc welding (DP-GMAW) creates a homogeneous molten pool with stable metal transfer characteristics. This process results in lower heat input while enhancing joint quality. To ensure the desired weld quality, process parameters must be optimized in accordance with the specific requirements of the application. In this study, low-carbon steel plates were joined using the DP-GMAW method. The optimization was performed using the Taguchi method, one of the design of experiments (DoE) techniques. Wire feed speed, pulse current, and frequency were selected as input variables. Tensile tests were carried out to evaluate mechanical performance and to investigate the influence of excessive weld metal. Accordingly, specimens were grouped as smooth and reinforcement specimens and tested under different parameter combinations. The contribution of each parameter was evaluated through analysis of variance (ANOVA), and the model's predictions were validated by experimental tests. According to the results, the optimum parameters for smooth specimens were a wire feed speed of 6.0 m/min, a pulse current of -3 %, and a frequency of 3 Hz, while those for reinforcement specimens were 6.8 m/min, -3 %, and 1 Hz. ANOVA results indicated that wire feed speed had the most significant effect on tensile strength among the parameters evaluated. The study demonstrated that the optimization of DP-GMAW process parameters using the Taguchi method led to reduced time and resource consumption and improved process efficiency.