An experimental study on optimizing for tandem gas metal arc welding process

Purpose: To enhance productivity and provide high quality production material in a GMA welding process, weld quality, productivity and cost reduction affects the number of process variables. In addition, a reliable welding process and conditions must be implemented to reduce weld structure failure. Design/methodology/approach: The research investigates the interaction between the welding parameters (welding speed, distance between electrodes, and flow rate of shielding gas) and bead geometry for predicting the weld bead geometry (bead width, bead height). Taguchi techniques are applied to bead shape to develop curve equation for predicting the optimized process parameters and quality characteristics by analysing the S/N ratio. Findings: The experimental results and measured error is within the range of 10% presenting satisfactory accuracy. The curve equation was developed in such a way that you can predict the bead geometry of constructed machinery that can be used for making tandem welding process. Research limitations/implications: In various industries the welding process mathematical model is not fully formulated for the process parameter and on the welding conditions, therefore only partial variables can be predicted. Originality/value: This paper focused on the anode-cathode distance that can prevent arc blow in tandem GMA welding process. We also analysed the welding quality characteristics according to the bead geometry and welding parameters through S/N ratio dependent on the welding speed and flow rate variation of shielding gas. Finally, a mathematical model being able to predict the welding quality based on the given welding parameters using statistical method has been developed.