Evaluate The Metal Inert Gas Welding Process Using Activated Flux On SS316L By ANN

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Prepared by: Guided by:Pavan Chaudhari Mr .J.D.Patel M.E.(Production) HOD MechanicalEn.No:140650728014

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Outline Introduction Literature review Summary of Literature review Research gap from Literature review Objective of present study Experimental setup Result sheet Optimization Method Result and discussion Conclusion Future Scope Work plan References

Introduction

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Gas Metal Arc Welding (GMAW) is an arc welding process that joins metals together by heating them with an electric arc that is established between a consumable electrode (wire) and the work piece.

Basic Principle of GMAW An arc is established between a

continuously fed electrode of filler metal and the work piece.

After proper settings are made by the operator, the arc length is maintained at the set value.

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Activated flux

The flux ingredient which is inorganic compound (which can be used to produce deep penetration and arc constriction) are available in variety of range and compositions.

Oxide coating consists of iron, chromium, silicon, titanium, manganese, nickel, cobalt, molybdenum and calcium are reported to improve weldability and increase the welding speed.

The halogens, calcium fluoride and AlF2 have claim to constrict the arc and increase weld depth of penetration .

Requirement of Activated flux

To improve weldability and increase the welding speed. To constrict the arc and increase weld depth of penetration . To reduce number of passes.

A-GMAW Process Description

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Available literatures show that some of the mechanisms, which play major role in increase depth of penetration, are given .

Mechanism of Activated flux

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Marangoni Effect.

Effect of arc constriction due to negative ions.

Effect of arc constriction due to insulating surface of flux.

Buoyancy force.

Electromagnetic force

Mechanism of Activated flux

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Marangoni Effect Arc constriction due to negative ions

Buoyancy force

Electromagnetic Force

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TITLE TIG welding with single-component fluxes

AUTHOR Modenesi Paulo J.

YEAR 2000

FLUX AlF3 , Al2O3 , Cr3O3 , CaF2 , Fe2O3 , Na2WO4 , SiO2 , TiO

MATERIAL 304 Stainless Steel

Input Parameter

Gas Type- Argon Gas Flow l0 L/minW.S. 20 cm/min Arc length 1±3 mm W.C. 200±300 A

Output parameter

Penetration

Conclusion penetration can be obtained in A-TIG welding using activated Fluxes 

LITERATURE REVIEW

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TITLE Mechanism and Optimization of Oxide Fluxes for DeepPenetration in Gas Tungsten Arc Welding

AUTHOR LU SHANPING, FUJII HIDETOSHI,

YEAR 2003

MATERIAL 304 stainless steel

FLUX Cu2O, NiO, SiO2, CaO, Al2O3

Input Parameter

Electrode type DCEN, W-2 pct ThO2 Diameter of electrode 1.6 mmShield gas Argon W.C. 160A W.S. 2 mm/s

Output parameter

Penetration

Conclusion Cu2O has a narrow effective flux-quantity range for the deep penetration

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TITLE Electron Beam Welding with Activating Flux

AUTHOR Ruihua Zhang

YEAR 2006

MATERIAL stainless steels

FLUX SiO2 ,TiO2 ,Cr2O3 ,FS12

Input Parameter

Welding speed 2-8mm/sec A.V 60kV Power 1500-2500WW.C. 22.5-58.4 A Electron beam size 0.2-0.5mm

Output parameter

Penetration

Conclusion Higher penetration Reduces B.W. at upper side, increase B.W. under side

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TITLE Effect of activating flux on arc shape and arc voltage intungsten inert gas welding

AUTHOR LI Qing-ming

YEAR 2007

MATERIAL Stainless Steel

FLUX SiO2, TiO2

Input Parameter W.C. 60-160A

Output parameter

Penetration

Conclusion Sio2 flux, arc deflected towards the rear of arc moving directionvoltage increase with increasing in current so flux evaporated

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TITLE Gas tungsten arc welding of magnesium alloy usingactivated flux-coated wire

AUTHOR Liu L.M., Cai D.-H.

YEAR 2007

MATERIAL magnesium AZ31B alloy

FLUX Mncl2, ZnO

Input Parameter Welding current 100 A Arc voltage 15–20 VTravel speed 240 mm/min Wire feeding rate 360 mm/min

Output parameter

Penetration

Conclusion Flux cored wire is more effective to increasing penetration.40% Mncl2 and 60% Zno make deep penetration

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TITLE Marangoni convection and weld shape variation in A-TIG welding process

AUTHOR Xu Y.L. , Dong Z.B., Y.H. Wei, C.L. Yang

YEAR 2007

MATERIAL Nimonic 263 alloy

FLUX TiO, TiO2, Ti2O3

Input Parameter W.C. 150 A W.S 1.5 mm/secA.V. 10 V

Output parameter

Penetration strength

Conclusion Flux on the top of the weld bead increase the penetration, effects ofarc constriction on the weld shape is very small. Reversed marangoni effect

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TITLE Effects of shielding gas composition and activating flux on GTAW weld ments

AUTHOR Huang Her-Yueh

YEAR 2009

MATERIAL 304 Stainless steel

FLUX MnO2, ZnO

Input Parameter W.S. 75mm/min , W.C. 125A , Arc voltage 13-17 V Shielding gas nitrogen 2.5-10 vol.% , Flow rate 20 µL/min

Output parameter

Penetration

Conclusion Nitrogen additions to an argon base gas will increase the heat input, heat to be transferred into specimens by the arc and consequently produced deep penetration.

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TITLE Effects of activating flux on the welded joint characteristics in Gas metal arc welding

AUTHOR Huang Her-Yueh

YEAR 2010

FLUX Fe2O3, SiO2, MgCO3

MATERIAL 1020 carbon steel

Input Parameter Arc voltage 20-23 V , W.C. 180-220 AW.S. 346-454mm/min

Output parameter

Penetration , tensile strength

Conclusion activating flux aided GMAW increased the weld area and penetration and tended to reduce the angular distortion of the weldment.

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Huang et.al. (2010)

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TITLE Research on the Activating Flux Gas Tungsten Arc Welding and PlasmaArc Welding for Stainless Steel

AUTHOR Huang Her-Yueh

YEAR 2010

MATERIAL 304 stainless steel

FLUX TiO2 , SiO2, Cr2O3, MoO3

Input Parameter W.C. 75-100-125A W.S. 150 mm/min Shielding gas -Ar, Gas flow rate 10L/min, 17.5L/min Plasma gas flow rate- 0.7L/min

Output parameter

Penetration

Conclusion Both GTAW and PAW with activating flux produced asubstantial increase in the depth of penetration

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TITLE Estimation and optimization of depth of penetration in hybrid CO2 LASER-MIG welding using ANN-optimization hybrid model.

AUTHOR Ghosal Sujit, Chaki Sudipto

YEAR 2010

MATERIAL 5005 Al–Mg alloy

Input Parameter Power P W, Focal distance F mm , Torch angle A deg.Distance between the laser and welding torch S mm

Output parameter

Penetration

Conclusion Output better than regression model, predicting, and optimizing operational parameters of any experimental study with single output by running only oneprogram under MATLAB7.0

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TITLE Performance of activated TIG process in austenitic stainless steel welds

AUTHOR Tseng Kuang-Hung

YEAR 2011

FLUX MnO2, TiO2, MoO3, SiO2, Al2O3

MATERIAL 316L stainless steels

Input Parameter Weld current 200A Travel speed 150mm/minDiameter of electrode 3.2mm Arc voltage 11-19VShielding gas - Pure argon Gas flow rate 10L/min

Output parameter

Penetration

Conclusion fluxes produced a significant increase in weld depth and a decrease in bead width

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Tseng et al.(2011)

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TITLE Effect of activated TIG flux on performance of dissimilar welds betweenmild steel and stainless steel

AUTHOR Cheng-Hsien Kuo, Tseng Kuang-Hung , Chang-Pin Chou

YEAR 2011

FLUX CaO, Fe2O3, Cr2O3, SiO2

MATERIAL JIS G3131mild steel and SUS 316L stainless steel

Input Parameter Weld current 200A Travel speed 150mm/minDiameter of electrode 3.2mm Gas flow rate 12L/min

Output parameter

Penetration

Conclusion SiO2 powder gives the greatest improvement in joint penetration

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TITLE Study of the characteristics of duplex stainless steel Activated Tungsten inertgas welds

AUTHOR Chern Tsann- Shyi

YEAR 2011

FLUX TiO2, MnO2, SiO2, MoO3, Cr2O3

MATERIAL 2205 stainless steels

Input Parameter W.C. 200 A W.S. 150 mm/minDiameter of electrode 3.2 mm Shielding gas Pure argon Gas flow rate 10L/min

Output parameter

Penetration, mechanical strength

Conclusion TIG welding with SiO2 flux produced a full joint penetration and the greatest weld depth-to-width ratio.

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TITLE Mechanical properties and microstructures of 6082-T6 joint welded by twinwire metal inert gas arc welding with the SiO2 flux

AUTHOR Y. Ruan

YEAR 2012

FLUX SiO2

MATERIAL 6082-T6 Al-alloy

Input Parameter Arc Voltage 19-21 V W.C. 210-220 A , W.S. 120cm/min

Output parameter

Penetration

Conclusion 26% deeper penetration than without using activated flux

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TITLE Optimization of laser welding process parameters for super austenitic stainless steel using artificial neural networks and genetic algorithm

AUTHOR Sathiya P. , Panneerselvam K., Abdul Jaleel M.Y.

YEAR 2012

MATERIAL 904L super austenitic stainless steel

Input Parameter Beam power 3-3.5 kW , Travel speed 2-3 m/minFocal position 0 - (-2)mm

Output parameter

Tensile strength, Bead width, Depth of penetration

Conclusion Relationship between the input and output parameter through ANN

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TITLE Experimental investigation on mechanism and weld morphology of activated TIG welded bead-on-plate weldments of reduced activation ferritic/martensitic steel using oxide fluxes

AUTHOR Vora Jay J., Badheka Vishvesh J.

YEAR 2015MATERIAL RAFM Steel

FLUX Co3O4 , CuO ,HgO, MoO3

Input Parameter W.C. 200 A Shielding gas Ar , 10-12L/min W.S. 100mm/min Electrode extension 5-6mm

Output parameter

Penetration

Conclusion Continuous penetration was achieved with the use of fluxes Co3O4and CuO, Reversed Marangoni effect was to be present as a depth enhancing mechanism  

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TITLE Effect of activating fluxes on weld bead morphology of P91 steel bead-on-plate welds by flux assisted tungsten inert gas welding process

AUTHOR Dhandhaa Kamal H., Badheka Vishvesh J.

YEAR 2015

MATERIAL P91 Steel

FLUX CaO, Fe2O3, TiO2, ZnO, MnO2 and CrO3

Input Parameter W.C. 200 A , Shielding gas Ar , Gas flow rate 10-12L/min, Dia.of electrode 2.9mm , W.S. 100mm/min, Electrode gap 2-3mm

Output parameter

Penetration

Conclusion increase in weld penetration and the decrease in bead width with the use of the activating fluxes.

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Summary of Literature Review:

•Input Parameter: welding current, Arc voltage, welding speed, filler wire diameter, shielding gas-gas flow rate, electrode diameter .

•Output Parameter: Penetration, Tensile strength, bead width

•Material: SS304, SS316, MgAZ31B, Nimonic 263, 1020 carbon steel , 904Lsteel P91 steel, SS2205

•Welding method: TIG, MIG, Electron beam welding, Plasma Welding

Research gap from Literature review

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It is obvious from the literature review that, most of researches worked on TIG,PAW,EBW using different activated flux but few work has been done on GMAW process yet so there is a scope of it.

The less work has been done for increasing its penetration as well as strength on SS316L yet.

Based on Research paper activating flux is play noticeable effective for GMAW process to increase penetration as well as strength.

Activating flux is most effective for GMAW process to increase penetration as well as strength

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Objective of Present study

To improve the penetration of welding joint.

To minimize number of passes of weld and hence increase productivity.

To find out the best types of activated flux which can give the better performance for this process.

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Experimental setupTable -1 Specification of PROSTAR MIG 350 welding machine

SPECIFICATION PROSTAR MIG 350Mains supply, Ph x V 3 x 415Open circuit voltage DC (Max) 69 VWelding current rangeWelding voltage range Frequency

40-350 A 16-31.5V 50Hz

Shielding gas ArType of cooling Forced AirWeight 40kg

Table 2- Specification of PROSTAR WF 60 MIG welding machine

SPECIFICATION WIRE FEEDER MACHINE

Drive system DC motor

Wire feed speed 1 – 24 m/min

Wire diameter

Weight

0.8-1.6mm

7kg

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Mig Welding Machine

Source : Keepsake Engineering Consultancy Pvt. Ltd. 2,Meldi Estate, Nr ,Railway crossing Gota

Ahemdabad

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Table 3 Chemical Composition of SS 316L

Table 4-Mechanical properties of SS 316L

Element Content (%)Moly 2.060Cr 16.210Ni 10.400Mn 1.300Si 0.240C 0.018P 0.039S 0.003

Properties Metric

Density 8000k g/m3

Tensile strength 485 MPa

Yield strength 170 MPa

Elastic modulus 193 GPa

Elongation 40%

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Table 5 Process parameterPROCESS PARAMETER CONSTANT PARAMETER

Welding Current (A) Electrode size (mm)

Active Flux Shielding Gas

Arc Voltage (V)

Welding speed (mm/min)

Table 6 Input Parameter

NO Factor Level 1 Level 2 Level 3 Unit

1 Arc Voltage 20 22 24 Voltage

2 Welding current 150 180 200 Ampere

3. Welding speed 150 170 180 mm/min

4. Active Flux SIO2 Cr2O3 _ _

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Table 7 Experimental parameter

Experiment

No

Welding

Speed

(mm/min)

Welding

current

(Amp)

Arc Voltage

(Volt)

1 150 150 20

2 150 180 22

3 150 200 24

4 170 150 22

5 170 180 24

6 170 200 20

7 180 150 24

8 180 180 20

9 180 200 22

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We have selected the material for experiment runs SS 316L as a base metal having size 100*50*6 (mm)

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WIRE SPOOL & CONTROLUNIT WELDING TORCH POWER SOURCE

WORK PIECE GAS CYLINDER AUTOMATION SOFTWARE MONITOR

EXPERIMENTAL SET UP

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MIG WELDING Machine used for Experiment at KEEPSAKE Pvt. Ltd

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L9 Orthogonal Array for Experimental runs (Without Activated Flux, SiO2, Cr2O3)

Experiment No Welding Speed

(mm/min)

Welding current

(Amp)

Arc Voltage

(Volt)

1 150 150 20

2 150 180 22

3 150 200 24

4 170 150 22

5 170 180 24

6 170 200 20

7 180 150 24

8 180 180 20

9 180 200 22

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MIG Welding Process

Silicon Dioxide (SIO2) Chromium(III) Oxide (Cr2O3.)

Plate with & without flux on Exp. setup

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Without flux Active Flux SIO2

Active Flux Cr2O3

Bead on Welding plate

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Measuring Equipment for Result

STEREO ZOOM MICROSCOPE

Computer Image of Work piece

VICKERS HARDNESS TESTER

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Experiment

NoWelding

Speed

(mm/min)

Welding

current

(Amp)

Arc

Voltage

(Volt)

Weld

Penetration

(mm)

Hardness

(HV)

1 150 150 202.97 207.67

2 150 180 222.5 205.67

3 150 200 24

4 170 150 221.92 188.67

5 170 180 241.82 185.67

6 170 200 202.06 194.67

7 180 150 242.09 192

8 180 180 202.59 188.33

9 180 200 223.1 197.00

Result of penetration & Hardness , without Activated Flux

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Experiment

NoWelding

Speed

(mm/min)

Welding

current

(Amp)

Arc

Voltage

(Volt)

Weld

Penetration

(mm)

Hardness

(HV)

1 150 150 20 3.75 206.67

2 150 180 22 3.6 198.33

3 150 200 24 3.7 199.67

4 170 150 22 3.9 185.33

5 170 180 24 3.95 202.33

6 170 200 20 4.81 193.38

7 180 150 24 4.01 189.67

8 180 180 20 4.28 194.33

9 180 200 224.77 191.67

Result of penetration & Hardness , with (SIO2)

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Experiment

NoWelding

Speed

(mm/min)

Welding

current

(Amp)

Arc

Voltage

(Volt)

Weld

Penetration

(mm)

Hardness

(HV)

1 150 150 203.9 206.00

2 150 180 223.6 201.67

3 150 200 243.8 184.33

4 170 150 224.21 184.33

5 170 180 244.24 213.67

6 170 200 203.94 194.33

7 180 150 243.88 188.33

8 180 180 203.5 197.00

9 180 200 224.15 185.67

Result of penetration & Hardness, with (Cr2O3)

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OPTIMIZATION METHOD

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Introduction to ANN• Useful networks which contain only one layer, or even

one element, most applications require networks that contain at least the three normal types of layers - input, hidden, and output.

• The layer of input neurons receives the data either from input files or directly from electronic sensors in real-time applications.

• The output layer sends information directly to the outside world, to a secondary computer process, or to other devices such as a mechanical control system.

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• Between these two layers can be many hidden layers. These internal layers contain many of the neurons in various interconnected structures.

• The inputs and outputs of each of these hidden neurons simply go to other neurons

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. Neural network applications

a)Business Applicationsb) Aerospacec)Automotived)Bankinge)Credit Card Activity Checkingf) Defenceg)Electronicsh)Entertainmenti) Financialj) Industrialk)Insurancel) Manufacturingm)Medical:n)Oil and Gaso)Telecommunications

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RESULT AND DISCUSSION

simulation chart- without flux

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simulation chart- with sio2 flux case

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simulation chart- with Cr2O3 flux case

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• When the programme run its generate 768 different location of the different set of parameter. Tool process on the all this set of different parameter and gives the best location of the parameter set.

Here, range of input parameter :

Welding current 150:2:200 Welding speed 150:2:180Arc voltage 20:2:24

Now the location generate in the programme are:[150 150 20] [150 150 22] [150 150 24] [150 152 20] [150 154 22]............................In this way all the location are generate for set of parameter.

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comparison chart of penetration

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No flux case which indicate with red colour. From graph studypenetration is up to 3mm in starting parameter set but after it suddenly fall down up to 2mm this fluctuation in this case occurred when the voltage value is increased but when current and welding speed increase its flow up the graph line give affective result.

Sio2 which indicate the blue colour, here penetration value is highest but in further experiments it is gradually goes to down. welding speed and welding current are mainly affect on the penetration.

Cr2o3 which indicate with the black colour, in this case penetration has the higher consistency. There is no fluctuation in this case.

55comparison chart of hardness

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No flux case show in red colour, here fluctuation in hardness in occurred.Increased value of voltage made reduction in hardness of the weld and its gradually reduced. welding speed make some changes in hardness.

Sio2 which indicate the blue colour, here hardness have higher value. In compare too other there No fluctuation in is occurred. So that flux increase the hardness. There is no change in metallurgy of the weld specimen.

Cr2o3 which indicate the black colour, with compare to all above experiment result this flux gives high penetration but, in case of hardness it is after the Sio2 due to higher heat input at the weld point which make the chemical effect on the material. The metallurgy structure affected by the weld parameter and changes in the mechanical property ofthe weld material.

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CONCLUSION

• This work has focused on the effect of Active flux on gas welding. Here, we have select three various input parameter like welding speed, welding current and arc voltage.

• The experiment had been done as per DOE, and two output result are consider for this work, which are weld penetration and Hardness

• Active flux have play a noticeable effect on penetration of the weld plate,which tested by Macro structure Examination and Hardness test.

• The output result of the experiment optimization by the ANN in MATLABwhich conclude that both flux give higher Penetration ,but sio2 flux has higher consistency with both output weld penetration and Hardness of material.

• With a visual inspection on the set of experiment, we had noticed that Arc constriction is the main mechanism for the higher penetration.

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FUTURE SCOPE

Further study on this thesis with changing in the flux powder or mixing the various flux.

Experiment possible will be with the change in welding current, welding speed, arc voltage.

If we will change the size of the electrode its also effect on the welding quality.

Experiment will be done with the change the material.

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Work Plan TENTATIVE

ACTION PLANJuly-15

Aug-15

Sept-15

Oct-15

Nov-15

Dec-15

Jan-16

Feb-16

Mar-16

Apri -16

May-

16

June-16

Topic

TOPIC SELECTION

LITERATURE REVIEW

1.Study paper 2.Find research gap & objective

METHODOLOGY 1.Study method 2.Learning Minitab

EXPWRIMENTAL WORK

1.Select parameter2. Performance and testing

RESULT ANALYSIS

1.Analysis of Work2.Publish the Paper

REPORTSUBMIT Preparation of Report

REFERENCE:

1.. Modenesi Paulo J, EustaAquio R. ApolinaArio, Iaci M. Pereira (2000)”TIG welding with single-component Fluxes”,Materials Processing Technology 99, 260-265.

2. Lu Shanping, Fujii Hidetoshi, Hiroyuki Sugiyama,and Kiyoshi Nogi(2003),” Mechanism and Optimization of Oxide Fluxes for Deep Penetration in Gas Tungsten Arc Welding”, Metallurgical And Materials Transactions A, 34A .

3. Ruihua Zhang , FAN Ding , Seiji Katayama,(2006),” Electron Beam Welding with Activating Flux” Transactions of JWRI, Vol.35.

4. Qing-ming , WANG Xin-hong, ZOU Zeng-da, WU Jun. (2007) , ” Effect of activating flux on arc shape and arc voltage in tungsten inert gas welding” ,Trans. Nonferrous Met. Soc. China I7, 486-490.

5. Liu L.-M., Cai D.-H. , Zhang Z.-D. (2007)” Gas tungsten arc welding of magnesium alloy using activated flux-coated wire” Scripta Materialia 57 , 695–698.

6. Xu Y.L. , Z.B. Dong, Y.H. Wei, C.L. Yang (2007),” Marangoni convection and weld shape variation in A-TIG welding process”,Theoretical and Applied Fracture Mechanics 48 ( 178–186)

7. Huang Her-Yueh,(2009)” Effects of shielding gas composition and activating flux on GTAW weldments”, Materials and Design 30, (2404–2409)

8. Huang Her-Yueh,(2010)” Effects of activating flux on the welded joint characteristics in gas metal arc welding”, Materials and Design 31, (2488–2495).

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9. Huang Her-Yueh,(2010)” Research on the Activating Flux Gas Tungsten Arc Welding and Plasma Arc Welding for Stainless Steel”, Met. Mater. Int., 16, No. 5 pp. 819~825.

10. Ghosal Sujit Chaki Sudipto(2010)” Estimation and optimization of depth of penetration in hybrid CO2 LASER-MIG welding using ANN-optimization hybrid model” Int J Adv Manuf Technol ,47,1149–1157

11. Tseng Kuang-Hung, Chih-Yu Hsu,(2011),” Performance of activated TIG process in austenitic stainless steel welds”, Journal of Materials Processing Technology 211, (503–512)

12. Kuo Cheng-Hsien, Tseng Kuang-Hung and Chou Chang-Pin,(2011),” Effect of activated TIG flux on performance of dissimilar welds between mild steel and stainless steel”, Key Engineering Materials,479,74-80.

13. Chern Tsann-Shyi, Tseng Kuang-Hung, Hsien-Lung Tsai(2011) ,”Study of the characteristics of duplex stainless steel activated tungsten inert gas welds”, Materials and Design 32 , (255–263).

14. Y. Ruan , X.M. Qiu , W.B. Gong , D.Q. Sun , Y.P. Li (2013),” Mechanical properties and microstructures of 6082-T6 joint welded by twin wire metal inert gas arc welding with the SiO2 flux”, Materials and Design 35 , (20–24)

15. Sathiya P., Panneerselvam K., Abdul Jaleel M.Y(2012)” Optimization of laser welding process parameters for super austenitic stainless steel using artificial neural networks and genetic algorithm” Materials and Design ,36 , 490–498

16. Vora Jay J., Badheka Vishvesh J.,(2015),” Experimental investigation on mechanism and weld morphology ofactivated TIG welded bead-on-plate weldments of reduced activationferritic/martensitic steel using oxide fluxesJ”, Journal of Manufacturing Processes, 356.

17. Dhandha Kamal H. ,Badheka Vishvesh J.(2015)” Effect of activating fluxes on weld bead morphology of P91 steel bead-on-plate welds by flux assisted tungsten inert gas welding process” Journal of Manufacturing Processes, 17 , 48–57 61

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WEBSITES www.sciencedirect.comwww.springer.comwww.elsevier.comwww.azom.com  BOOKS • O. P. KHANNA “A textbook of Welding Technology”, Dhanpat Rai Publications.

• R S Parmar, Welding processes and Technology, 3rd Edn, Khanna Publishers, 2013

• AWS Hand book [Volume 2 Welding Processes]

• ASM Hand book [Volume 6 Welding, Brazing and Soldiering]

THANK YOU

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