Effects of Process Parameters on the Bead Shape in the Tandem Gas Metal Arc Welding of Aluminum 5083-O Alloy

Author:

Kim Gwang-Gook12ORCID,Kang Taehoon1,Kim Dong-Yoon12ORCID,Kim Young-Min1ORCID,Yu Jiyoung1,Park Junhong2ORCID

Affiliation:

1. Advanced Joining & Additive Manufacturing R&D Department, Korea Institute of Industrial Technology, 156 Gaetbeol-ro, Yeonsu-gu, Incheon 21999, Republic of Korea

2. Department of Mechanical Convergence Engineering, Hanyang University, Seoul 04763, Republic of Korea

Abstract

In gas metal arc welding (GMAW), the weld bead shape is an important factor that is directly related to the weld quality of welded joints. This study investigates the effects of process parameters, including welding speed (WS) and leading and trailing wire feed rates (WFR), on the weld bead shape, including the leg length and penetration depth, in the tandem GMAW of aluminum 5083-O alloy. An asynchronous direct current–direct current pulse tandem GMAW system and a tandem GMAW torch were designed and applied to improve welding productivity and welding quality. Response surface methodology was used to analyze the effects of the process parameters on the weld bead shape and to estimate regression models for predicting the weld bead shape. As a result of observing arc behavior using a high-speed camera, it was confirmed that the leading WFR affects the penetration depth and the trailing WFR affects the leg length. The coefficient of determination (R2) of the regression models was 0.9414 for the leg length and 0.9924 for the penetration depth. It was also validated that the estimated models were effective in predicting the weld bead shape (leg length and penetration depth) representative of weld quality in the tandem GMAW process.

Funder

Korea Institute of Industrial Technology

Publisher

MDPI AG

Subject

Fluid Flow and Transfer Processes,Computer Science Applications,Process Chemistry and Technology,General Engineering,Instrumentation,General Materials Science

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