Abstract

Optimization of flux cored arc welding (FCAW) process parameters were carried out to obtain optimum weld bead geometry in mild steel plates of IS 2062 by using an alternate Taguchi method. Design of experiments based on multi-objective Taguchi approach was employed for development of mathematical model correlating important process parameters like welding voltage (V), welding current (I), stick out (N) and wire speed (T), with weld bead parameters like penetration (P) and percentage of dilution as responses. The optimum welding parameters were investigated using Taguchi method with L₁₆ orthogonal array (OA). The developed models have checked for adequacy and significance based on analysis of variance (ANOVA) test. Because of high reliability, easiness in operation, high penetration good surface finish and high productivity FCAW became a natural choice for fabrication industries. Based on confirmation test, the proposed model can be effectively used to optimize the welding performance. The utility concept was used for optimization of bead geometry and results are presented.

Key words: Flux cored arc welding (FCAW), optimization, analysis of variance (ANOVA), Taguchi approach, utility concept