Optimization of Bead Geometry during Tungsten Inert Gas Welding Using Grey Relational and Finite Element Analysis

Mild steel welded products are widely used for their excellent ductility. Tungsten inert gas (TIG) welding is a high-quality, pollution-free welding process suitable for a base part thickness greater than 3 mm. Fabricating mild steel products with an optimized welding process, material properties, a...

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Bibliographic Details
Published in:Materials 2023-05, Vol.16 (10), p.3732
Main Authors: Hanif, Muhammad, Shah, Abdul Hakim, Shah, Imran, Mumtaz, Jabir
Format: Article
Language:English
Subjects:
Aluminum
Carbon steel
Content analysis
Electric potential
Experiments
Finite element analysis
Finite element method
Flow velocity
Friction stir welding
Gas flow
Gas tungsten arc welding
Gas welding
Geometry
Heat flux
Inert gas welding
Low carbon steels
Material properties
Mechanical properties
Metals
Optimization
Optimization techniques
Process parameters
Rare gases
Residual stress
Stainless steel
Steel alloys
Steel, Structural
Stress distribution
Taguchi methods
Technology application
Temperature distribution
Thermal stress
Voltage
Welded joints
Welding
Welding current
Welding parameters
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Summary:Mild steel welded products are widely used for their excellent ductility. Tungsten inert gas (TIG) welding is a high-quality, pollution-free welding process suitable for a base part thickness greater than 3 mm. Fabricating mild steel products with an optimized welding process, material properties, and parameters is important to achieve better weld quality and minimum stresses/distortion. This study uses the finite element method to analyze the temperature and thermal stress fields during TIG welding for optimum bead geometry. The bead geometry was optimized using grey relational analysis by considering the flow rate, welding current, and gap distance. The welding current was the most influential factor affecting the performance measures, followed by the gas flow rate. The effect of welding parameters, such as welding voltage, efficiency, and speed on the temperature field and thermal stress were also numerically investigated. The maximum temperature and thermal stress induced in the weld part were 2083.63 °C and 424 MPa, respectively, for the given heat flux of 0.62 × 10 W/m . Results showed that the temperature increases with the voltage and efficiency of the weld joint but decreases with an increase in welding speed.
ISSN:1996-1944
1996-1944
DOI:10.3390/ma16103732