Optimization of shielded metal arc welding process parameters for IS 2062 E250 steel using Taguchi’s L16 method

This study investigates the optimization of Shielded Metal Arc Welding (SMAW) parameters for IS 2062 E250 structural steel using the Taguchi L16 orthogonal array. Four critical process parameters as welding current (90–120 A), root face (1–4 mm), root gap (2–3.5 mm), and groove angle (30°–60°) were evaluated for their influence on tensile strength, impact strength, hardness, and angular distortion. Experimental results show that tensile strength varied from 231.56 to 447.12 MPa, with the maximum value 447.12 MPa obtained at 90 A welding current, 1 mm root face, 2 mm root gap, and 30° groove angle. The impact strength ranged from 23.3 to 264.5 J, with the highest value at 120 A current, 1 mm root face, 3.5 mm root gap, and 40° groove angle. This being said that the material gets stronger when it gets hotter and the joint shape gets bigger. The hardness levels were between 22.2 and 37.2 HRB. Higher hardness was associated with narrower groove angles and reduced welding currents. Moreover, the angular distortion ranged from 0.4° to 2.1°, with balanced joint shape and low current levels leading to the least distortion. According to the results of ANOVA, the welding current has an imperative effect on tensile strength, hardness, and angular distortions. Moreover, the groove directly affects the impact strength. Overall, the present work suggests direct relevant with the structural and industrial welding implications.