Effect of Welding Current, Arc Voltage and Gas Flow Rate on Depth of Penetration during MIG Welding of AA2014 Plate

1. International Journal of Advanced Research in Technology, Engineering and Science (A Bimonthly Open Access
Online Journal) Volume2, Issue2, March‐April, 2015. ISSN: 2349‐7173(Online).
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Effect of Welding Current, Arc Voltage and Gas
Flow Rate on Depth of Penetration during MIG
Welding of AA2014 Plate
R.Sakthivel1*
, P.Venkadeshwaran1
, R.Sridevi1
, R.Ahamed Meeran1
, K.Chandrasekaran1
.
____________________________________________
Abstract:
In the present work, bead-on -plate welds were carried
out on AA2014 Aluminum Alloy plate using Metal Inert
Gas Welding (MIG) process. In this present investigation
ER4043 solid wire having 1.2 mm diameter was used as
an electrode with direct current electrode positive
polarity. An argon gas was employed for shielding
purposes. The fusion zone is generally characterized by a
few geometrical features namely bead width,
reinforcement and depth of penetration. The shape of the
fusion zone depends upon a number of parameters such
as gas flow rate, voltage and welding current. Taguchi
Technique is applied to plan the experiments. The weld
bead geometry plays an important role in determining the
mechanical properties of a weld joint. Therefore, it is
important to set up proper welding parameters to produce
a good weld bead.
______________________________________________
Keywords: MIG welding, AA2014 plate, Taguchi
orthogonal array, bead geometry.
___________________________________________
1. Introduction:
Metal Inert Gas welding (MIG) process is an important
component in many industrial operations. The GMAW
parameters are the most important factors affecting the
quality, productivity and cost of welding [1].GMAW
process a continuous and consumable wire electrode is
used. A shielding gas generally argon or sometimes
mixture of argon and carbon dioxide are blown through a
welding gun to the weld zone. Electrode melts due to the
heat and molten filler metal falls on the heated joint [2].
Machinability of aluminum alloy 2014 is very good.
Typical applications of aluminum alloy 2014 are high
strength components especially for use in the aerospace
and marine industries .The aluminum alloys and copper are
difficult to weld because of the high thermal conductivity,
high thermal expansion and a tendency to give porous
welds. T6 - Solution heat treated and artificially aged [3].
During a manual welding operation, the welder has to have
control over the welding variables, which affect the weld
penetration, bead geometry and the overall weld quality. A
proper selection of welding variables will increase the
chances of producing welds of a satisfactory quality
[4].The weld and bead geometry plays an important role in
determining the mechanical properties of the weld [5].
Hence the input welding process variables which influence
the bead geometry must therefore be properly selected to
obtain an acceptable high quality joint [6]. They conducted
experiments based on five process parameters to obtain
bead geometry using GMAW process. From the study it
was inferred that welding voltage, arc current, welding
speed and welding angle have large significant effects on
bead geometry developed an approach to predict and
optimize weld bead geometry in GMAW [7].The bead
geometry and penetration affect the weldments
characteristics and are dependent on a number of welding
variables. In the present investigation an attempt was made
to study some of the weldments characteristics such as
bead height, bead width and depth of penetration, as
affected by welding parameters like arc-voltage, travel
speed, wire feed rate and gas flow rate. And also its effect
of the microstructural changes in the weld zone and
hardness variation across the bead on the MIG welded
AA2014 plate [8]. Dr. Taguchi of Nippon Telephones and
Telegraph Company, Japan has established a method based
on "orthogonal array" experiments which gives much
reduced "variance" for the experiment with "optimum
settings" of control variables. Thus the marriage of Design
of Experiments with optimization of control parameters to
find best results is attained in the Taguchi Method. Taguchi
technique is used to increases the output and reduced the
cost of the products. The Taguchi Design is based on
orthogonal array. Taguchi design recognizes the control
factors to minimize the effect of Noise factor. Orthogonal
array helps to reduced the time and cost of the experiment.

2. Int
All R
The
requ
optim
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2. L
Liter
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in M
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para
lead
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requ
inve
were
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for
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and
ternational Jo
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Signal-to-Noi
uired output, w
mized [9]. A
Fig.2. A Schem
Literature Rev
rature shows t
ects of modelin
MIG welding. I
de to establ
ameters and w
ding to an opti
E using Taguch
uired for exp
estigation, in th
e used to c
tributions of ea
ngs.
dele, et al.[10]
investigation
age is used as p
ngth, Since in
current, the tw
ournal of Adv
Online Jour
ed©2015 IJA
se (S/N) Ratio
which is the
Schematic Di
matic diagram
views
that work has
ng, simulation
In this study,
lish relations
weld bead ge
imal process.
hi approach ca
perimental inv
he first stage, T
conduct the e
ach factor and
] Worked on W
using MIG w
parameters cur
n arc welding
wo conditions
vanced Resea
rnal) Volume2
ARTES
o which are log
objective fun
agram of GM
Fig.1. A
of weld bead g
been explored
n and process
detailed analy
ships betwee
ometry and w
P K Palani, e
an significantly
vestigations 6
Taguchi's ortho
experiments t
to optimize th
Wrought alum
welding .The
rrent and volta
is directly rel
are applied i.e
arch in Techn
2, Issue2, Ma
Visi
g function of
nction to be
MAW System
A Schematic D
geometry
d on various
optimization
ysis has been
en welding
weld quality
et al.[9] The
y reduce time
6-8. In this
ogonal arrays
to find the
he parameter
minum alloy
current and
age on tensile
lated voltage
e. at constant
ology, Engine
arch‐April, 20
it: www.ijarte
has be
bead pe
Figure
Diagram of GM
current
voltage
V2=30
100A.T
and oth
V2=30
way of
alloys,
difficul
arc, str
welded
nature
general
with o
al.[12]
are cut
first sa
edge o
transve
study o
with v
180, 32
was us
the etc
dimens
metal.
the bea
charact
variabl
to study
height,
welding
rate an
eering and Sc
015. ISSN: 234
es.org
en shown in F
enetration in w
2.
MAW System
t the welding
e the current w
V.Tensile stre
Toughness prop
her are nearer t
V.Latfe,et al.[
f joining vario
notably those
lt to fusion we
ruck between
d, to generate
of aluminum,
lly argon, pro
oxygen, nitroge
After the wel
t from each we
ample being lo
of the crater e
erse faces of th
of weld bead
arious grades
20, 400, 800,
ed as coolant.
ched sample
sions of the we
Sathiya, et al.[
ad geometry a
teristics and ar
es. In the prese
y some of the
bead width an
g parameters li
nd gas flow
cience (A Bim
49‐7173(Onli
Figure 1. A s
welding applica
voltage was
was I1=75A & I
ength is mor
perty is found
to it. Hardness
11] MIG weld
ous aluminum
e in the 2XXX
eld. MIG weld
the filler rod
e localized he
the arc is shr
otecting the ba
en or hydroge
lding process,
eld bead at 15
ocated at 15 m
end to elimina
he specimens w
geometry. Sp
of emery pap
1200 and SIA
The bead geo
by optical m
eldment were m
[13]Summarizi
and penetratio
re dependent o
ent investigatio
weldment char
nd depth of pen
ike arc-voltage
rate. And a
monthly Open
ne).
schematic illus
ations has been
varied as V1
I2=100A and a
re when curr
d to be good at
is more at I1=
ding is a well e
m alloys, althou
X and 7XXX s
ding employs a
and the mate
eat.Due to the
rouded by an
ase metal from
en. Rakesh Sh
the weld bead
mm intervals
mm behind th
ate the end eff
were further pre
pecimens were
pers, starting w
A Signor B 160
ometry was me
microscopy. T
measured from
ing, it can be s
on affect the
on a number o
on an attempt w
racteristics suc
netration, as af
e, travel speed,
also its effec
n Access
Page 2
stration of
n shown in
1=25V &
at constant
rent is at
t V1=25V
=75A & at
stablished
ugh some
series, are
an electric
rial being
e reactive
inert gas,
m contact
harma, et
d samples
s, with the
he trailing
fects. The
epared for
e polished
with 150,
00. Water
easured on
The bead
m the base
stated that
weldment
of welding
was made
ch as bead
ffected by
wire feed
ct of the

3. Int
All R
micr
varia
(UN
3.E
The
plate
was
weld
take
the a
T
M
A
F
var
Cu
V
Ga
Samp
ternational Jo
Rights Reserv
rostructural ch
ation across th
NS N08904) sup
Exprimental D
experiments w
es of size 150
used in exper
ding area. ER 4
n as electrode
actual experim
Table 2. Level
Table 3
Material
AA2014
iller wire
ER4043
riables U
urrent A
oltage v
as flow
rate
Lit
ple no C
1
2
3
4
5
6
7
8
9
ournal of Adv
Online Jour
ed©2015 IJA
hanges in the
he beads on the
per austenitic s
Details
were carried on
0mm × 50mm
riments as it co
4043 electrode
e for this expe
ment a number
l of GMAW w
3. L 9 orthogon
Cu M
4.2 0
Cu M
0.30 0.
Unit Leve
Amp 180
volt 24
t/min 17
Current
(A)
V
180
180
180
200
200
200
220
220
220
vanced Resea
rnal) Volume2
ARTES
weld zone a
e GMA welded
stainless steel.
n AA2014 alum
× 6mm. GMA
oncentrates the
es of diameter 1
riment. Before
r of trial exper
Table 1. Ch
welding process
nal array desig
Mg Mn
0.6 0.2
Mg Mn
.05 0.05
el-1 Level-2
0 200
4 26
7 19
Voltage
(V)
24
26
28
24
26
28
24
26
28
arch in Techn
2, Issue2, Ma
Visi
and hardness
d AISI 904 L
minum alloy
AW welding
e heat in the
1.2 mm were
e performing
riments have
hemical compo
s variable
gn
Fe
0.5
Fe
0.8
2 Level-3
220
28
21
Gas flow
rate (L/min)
17
19
21
19
21
17
21
17
19
ology, Engine
arch‐April, 20
it: www.ijarte
been p
where w
like u
geomet
microsc
measur
of AA
Factors
given
orthogo
osition of base
4. Res
The m
Figure
is clean
the exp
measur
geomet
importa
general
amount
penetra
Si
0.7
Si
4.5
)
eering and Sc
015. ISSN: 234
es.org
performed to
welding could
undercutting a
try was measu
copy. The bea
red from the b
A2014 and the
s affecting the
in table 2 an
onal array are g
metal and fille
sult and Discu
macrograph of
3, It is observ
n and good. Th
perimental run
rement. The ex
try are presen
ant factor for
l, due to the h
t of heat depo
ation.
Fig.3. Macro
Zn
0.2 0
Zn
0.10 0
cience (A Bim
49‐7173(Onli
get the appro
be possible an
and porosity
ured on the et
ad dimensions
base metal. Th
e filler materia
GMAW weld
nd the experim
given in table 3
er wire used
ussion
the welded s
ed that the sur
he weld zone, if
ns is consider
xperimental re
nted in Table
determining
high amount o
osited on the
ograph of the w
Ti C
0.15 0.
Ti B
0.20 0.00
monthly Open
ne).
opriate parame
nd no observab
occurred. T
tched sample b
of the weldm
e chemical co
al is given in
ding and their
mental layout
3.
sample is pre
rface of the we
f free from cra
red for bead
esults for the w
4. Heat input
the bead geo
of heat input i
surface leads
welded sampl
Cr A
1 REM
r A
033 RE
n Access
Page 3
eter range
ble defects
The bead
by optical
ments were
mposition
n table 1.
levels are
using L9
esented in
elded plate
cks for all
geometry
weld bead
plays an
ometry. In
i.e., larger
to higher
le
Al
M 95.17
Al
EM

4. International Journal of Advanced Research in Technology, Engineering and Science (A Bimonthly Open Access
Online Journal) Volume2, Issue2, March‐April, 2015. ISSN: 2349‐7173(Online).
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Sample no Current
(A)
Voltage
(V)
Gas flow
rate (L/min)
Depth of
penetration
(mm)
Bead width
(mm)
Bead height
(mm)
1 180 24 17 7.28 11.99 1.92
2 180 26 19 7.33 11.9 2.05
3 180 28 21 7.38 12.0 2.90
4 200 24 19 8.20 12.4 3.30
5 200 26 21 7.38 12.0 2.78
6 200 28 17 8.10 12.24 3.26
7 220 24 21 7.22 12.23 1.58
8 220 26 17 7.96 14.29 3.24
9 220 28 19 7.16 15.20 3.02
Table 4. Experimentally measured values
4.1 Level average response analysis using average value
The level average analysis is based on combining and
averaging the response associated with each level for each
factor. From the average data of each of the experiments
where in one level of each factor occurs, the optimum
value of factors is determined. For the analysis of weld
quality generated by MIG welding process, penetration,
bead width and bead height of the weld were considered.
From the level average response analysis using the average
values of each trial run, the optimum conditions for each of
the factors Voltage (V), Welding Current (I) and Gas Flow
Rate (G) can be determined. Average effect of current on
bead dimensions are given in Table 5, Average effect of
welding voltage on bead dimensions 6 and Average effect
of gas flow rate on bead dimensions 7.
Table 5. Average effect of welding current on bead
dimensions
Welding
Voltage
(V)
Depth of
penetration
(mm)
Bead
width
(mm)
Bead
height
(mm)
24 7.57 12.20 2.27
26 7.56 12.73 2.69
28 7.55 13.14 3.06
Table 6. Average effect of voltage on bead dimensions
Welding Gas
flow
rate (L/min)
Depth of
penetration
(mm)
Bead
width
(mm)
Bead
height
(mm)
17 7.78 12.84 2.80
Welding
Current
(A)
Depth of
penetration
(mm)
Bead
width
(mm)
Bead
height
(mm)
180 7.33 11.96 2.29
200 7.89 12.22 3.12
220 7.45 14 2.62

5. Int
All R
1
2
4.1
The
effec
the p
widt
An e
size
meta
slug
curre
the e
caus
weld
the w
bead
4.1
In M
pene
incre
and
of t
decr
grea
ternational Jo
Rights Reserv
19
21
Table 7. Ave
1.1 Effect of cu
value of weld
ct on the depo
penetration. th
th of the weld p
excessively lo
produces a po
al on the surfac
gish, the bead
ent is too high
excessive deep
ses burn-throu
ding current a
weld metal and
d dimensions a
Fig.4. Effe
1.2 Effect of v
MIG the arc
etration, the b
easing the arc
wider, the pen
the voltage is
rease. Low v
ater convexity
ournal of Adv
Online Jour
ed©2015 IJA
7.56
7.33
erage effect of
dimensio
urrent on bead
ding current use
sition rate, the
he current will
penetration and
w welding cur
oor penetration
ce of the base
d is rough and
h, the size of t
p penetration t
gh and underc
lso affects the
d the tensile str
are shown in fig
ect of current o
voltage on bead
voltage has a
bead reinforcem
c voltage the w
netration increa
s reached, at
voltage produc
(high crown
vanced Resea
rnal) Volume2
ARTES
13.17
12.08
gas flow rate o
ons
d dimensions
ed in MIG has
weld bead siz
increase the d
d the size of th
rrent for a giv
and the pileup
metal transfer
d reinforcemen
the weld bead
that wastes the
cut. Too high
e mechanical p
rength. Effect o
gure 4.
on bead dimens
d dimensions
a decided effe
ment and bead
weld bead bec
ases until an op
which time i
ces narrower
n), but an ex
arch in Techn
2, Issue2, Ma
Visi
2.79
2.42
on bead
s the greatest
ze, shape and
depth and the
he weld bead.
ven electrode
p of the weld
by the arc is
nt high If the
is large and
e filler metal
h or too low
properties of
of current on
sions
ect upon the
d width. By
comes flatter
ptimum value
it begins to
beads with
xcessive low
ology, Engine
arch‐April, 20
it: www.ijarte
voltage
the we
shown
4.1.3
Argon,
many
alloys.
smaller
cheape
produc
weld b
penetra
is used
the con
argon i
are sho
Fi
eering and Sc
015. ISSN: 234
es.org
e may cause po
eld bead. Effec
in figure 5.
Fig.5. Effect
Effect of g
helium and
applications f
These inert ga
r penetration
r than helium
es less spatter
bead penetratio
ation and conv
d, welding volt
nsumption of sh
is used. Effect
own in figure 6
ig.6. Effect of
cience (A Bim
49‐7173(Onli
orosity and ove
ct of voltage o
of voltage on b
as flow rate
argon-helium
for welding n
as mixtures pro
and narrow b
and helium-arg
r. Unlike argo
on profile (high
vex surface pro
tage rises for t
hielding gas in
t of gas flow r
.
gas flow rate o
monthly Open
ne).
erlapping at the
on bead dimen
bead dimension
on bead di
m mixtures are
non-ferrous m
ovide lower me
bead contour.
gon mixtures a
n, helium imp
her melting ra
ofile). But, whe
the same arc l
ncreases more t
rate on bead di
on bead dimens
n Access
Page 5
e edges of
nsions are
ns
imensions
e used in
metals and
elting rate,
Argon is
and it also
proves the
ate, deeper
en helium
ength and
than when
imensions
sions

6. Int
All R
4.1
The
Figu
micr
pene
ternational Jo
Rights Reserv
1.4 Macrograp
smooth bead
ure 2. The fusi
ro graphs. In
etration is parti
ournal of Adv
Online Jour
ed©2015 IJA
ph of the Bead
d profile micro
ion line zone i
Figure 7 (sam
ially full in all
vanced Resea
rnal) Volume2
ARTES
d geometry Pr
o graphs are p
is clearly visib
mple 1 to 9) t
the micro grap
arch in Techn
2, Issue2, Ma
Visi
ofiles
presented in
ble in all the
the depth of
phs.
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arch‐April, 20
it: www.ijarte
Fi
The pre
under
outcom
1.The
penetra
increas
2.The
penetra
increas
3.The
penetra
[1] S. V.
welding
Engineer
[2] Kulek
[3] Alum
[4] Ram
on Mate
Departm
of Techn
[5], Y.S.
GTAW b
554.
[6] Mos
paramete
Materials
[7] Farh
predictin
eering and Sc
015. ISSN: 234
es.org
ig.7. Macrogra
5. Conclusio
esent focus on
different weld
me of this resea
effect of wel
ation is constan
sed.
effect of ar
ation is constan
sed.
effect of gas
ation, the bead
. Sapakal, M. T. T
using Taguchi des
ring Research and
kci, M. 2005 Meta
minum welding gui
anaiah, N. 2004 I
rials Science and
ment of Metallurgic
nology Madras.
and W.H.,Yang,
by Taguchi metho
tafa, N.B and M
ers for weld penet
s and Manufacturi
had Kolahan and
ng and optimizing
cience (A Bim
49‐7173(Onli
aph of the Bead
ons
n MIG welding
ding condition
arch.
lding current
nt, the bead wi
rc voltage in
nt, the bead wi
s flow rate i
width and bea
References
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7. International Journal of Advanced Research in Technology, Engineering and Science (A Bimonthly Open Access
Online Journal) Volume2, Issue2, March‐April, 2015. ISSN: 2349‐7173(Online).
All Rights Reserved©2015 IJARTES Visit: www.ijartes.org Page 7
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Biography
Mr.R.Sakthivel,(B.E)., Department of
Mechanical engineering., Nadar Saraswathi College of
Engineering and Technology., Theni. He had published one
paper in refereed International Journal and Conference.
Mr.P.Venkadeshwaran,(B.E)., Department of Mechanical
engineering., Nadar Saraswathi College of Engineering and
Technology., Theni. He had published one paper in
refereed International Journal and Conference.
Mrs.R.Sridevi,(B.E)., Department of Mechanical
engineering., Nadar Saraswathi College of Engineering and
Technology., Theni. She had published one paper in
refereed International Journal and Conference.
Mr.R.Ahamed Meeran, B.E., (M.E)., obtained his Bachelor
Degree in Mechanical Engineering in Nehru Institude of
Engineering and Technology, Coimbature.and Master
Degree in Manufacturing Engineering from Mother Terasa
College of Engineering and Technology,Pudukottai. He
had published two paper in refereed International Journal
and Conferences.
Dr. K.Chandrasekaran, B.E., M.E., PhD, MISTE, obtained
his Bachelor Degree in Mechanical Engineering and
Master Degree in Manufacturing Engineering from Anna
University Chennai and Anna University of Technology
Tiruchirappalli. He completed his PhD in the area of
Manufacturing Engineering and Optimization from Anna
University, Chennai. Now he is working as an Assistant
Professor in Nadar Saraswathi College of Engineering
College, Theni. He had published number of papers in
refereed International Journals and Conferences.
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Authors Address:
1
Department of Mechanical Engineering, Nadar
Saraswathi College of Engineering and Technology,
Theni, Tamilnadu, India.
*
Corresponding Author Email ID:
sakthi.rajen71@gmail.com
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