Optimization of gas tungsten arc welding parameters for welding of super duplex stainless steel using factorial design

Abstract

This study investigates the relationship between four welding input parameters (voltage, current, heat input, and welding speed) and the ultimate tensile strength (UTS) and yield strength (YS) of a welded joint. The work joined two super-duplex stainless-steel pipes of outside diameter 0.630 inches (16.002 mm) and a thickness of 0.065 (1.651 mm), using Gas Tungsten Arc Welding. Factorial design was used to ascertain the main and interaction effects of the welding input parameters on the UTS and YS of the welded joint. Results revealed a significant interaction between voltage, current, welding speed and heat input for UTS, and a significant interaction between the welding speed and heat input for YS. Results further revealed that as voltage increases from 9.3 V to 11.6 V, the UTS decreases by 2.69 MPa, while YS increases significantly by 24.25 MPa. When the current increases from 30 A to 38 A, the UTS increases by 10.81 MPa, while the YS increases by 4.25 MPa. In the case of the welding speed, an increase from 0.46 to 0.71 mm/s results in a decrease of the UTS by 7.94 MPa and a significant increase of the YS by 33.25 MPa. When the heat input increases from 0.54 to 0.70 kJ/mm, the UTS decreases by 15.06 MPa, whereas the YS decreases significantly by 35.25 MPa. Also, the optimum voltage, current, welding speed and heat input for UTS are 11.60 V, 30.0 A, 0.71 mm/s, and 0.70 kJ/mm, respectively, and those of YS are 9.30 V, 30.0 A, 0.46 mm/s, and 0.70 kJ/mm, respectively.