The Study on Effect of Process Parameters on Weld Deposits in Pulsed Gas Metal Arc Welding

Pulsed gas metal arc welding is one of the most widely used processes in the industry. It offers spray
metal transfer at low average currents, high metal deposition rate, versatility, less distortion, and the ability to be used
in automated robotic welding systems. The weld bead plays an important role in determining the mechanical properties
of the weld. Its geometric parameters, viz., width, reinforcement height, and penetration, are decided according to the
welding process parameters, such as welding voltage, welding speed, pulse current magnitude, frequency (cycle time),
etc. Therefore, to produce good weld bead geometry, it is important to set the proper welding process parameters. In
this project, mathematical models that correlate welding process parameters to weld bead geometry are developed with
experimental investigation. Taguchi methods are applied to plan the experiments. Five process parameters, viz.,
welding speed, plate thickness, pulse frequency, pulse current magnitude, welding voltage etc and base material as
stainless steel (SS grade 410) are selected to develop the models using multiple regression analysis. The models
developed were checked for their adequacy. Results of confirmation experiments show that the models can predict the
bead geometry with reasonable accuracy