Design of Experiment commonly referred to as DOE is one of the extensively used methods for experimental study of many manufacturing processes in engineering. DOE is a statistical approach in which a mathematical model is developed through experimental runs. DOE predicts possible output based on the input parameters of the experimental setup. In the present study, a review is made on DOE techniques that have been employed for various welding processes by other researchers. This study predominantly focuses on the usage of Response Surface Method, Taguchi's method and Factorial method in Welding.

/pdf/application-of-design-of-experiments-to-plasma-arc-welding-2ve9xgp8k3.pdf

Application of Design of Experiments to Plasma Arc Welding Process

Review on Application of Response Surface Method based Design of Experiments to Welding Processes

Hardfacing is one of the techniques used for part lifecycle elongation. Despite being used for over 100 years, there still is much to discover, as modern metallurgy provides more and more sophisticated alloys, which then have to be studied to find the best technological parameters in order to fully utilize complex material properties. One of the most efficient and versatile hardfacing approaches is Gas Metal Arc Welding technology (GMAW) and its cored-wire equivalent, known as FCAW (Flux-Cored/Cored Arc Welding). In this paper, the authors study the influence of heat input on the geometrical properties and hardness of stringer weld beads fabricated from cored wire consisting of macrocrystalline tungsten carbides in a nickel matrix. The aim is to establish a set of parameters which allow to manufacture wear-resistant overlays with high deposition rates, preserving all possible benefits of this heterogenic material. This study shows, that for a given diameter of the Ni-WC wire, there exists an upper limit of heat input beyond which the tungsten carbide crystals may exhibit undesired segregation at the root.

/pdf/on-the-influence-of-heat-input-on-ni-wc-gmaw-hardfaced-3m9uqfio.pdf

On the Influence of Heat Input on Ni-WC GMAW Hardfaced Coating Properties

The aim of the Plasma Transferred Arc (PTA) hardfacing process is improving a technical surface locally with a dedicated material; Hardfacing became an issue of intense development related to wear resistant application. The hardfacing procedures can be differentiated by the intensity of mixture with the base body, which is usually increasing along with an increasing fusion efficiency rate. Nearly all kinds of weldable materials can be hardfaced and mostly all types of known wear resistant metals in combination can be used as hardfacing materials. The PTA hardfacing process has been widely employed due to several advantages such as higher volume of metal deposition rates and achieving very low dilution level. Heat input which influences dilution can be controlled by proper selection of PTA process parameters. In this study, an attempt has been made to analyze PTA hardfacing of IS: 2062 structural steel with Titanium Carbide (TiC). Experiments were conducted based on a fully replicable five-factor, five-level central composite rotatable design. Mathematical models were developed using response surface methodology to study the effects of PTA hardfacing process parameters such as welding current, welding speed ,powder feed rate, oscillation width and pre heat temperature on bead geometry parameters like penetration, reinforcement, bead width and dilution. Direct and interaction effects of PTA process parameters on bead geometry were analyzed. From mathematical model, the process parameters were optimized.

Deign of Experiment and Optimization of Plasma Transferred Arc Hardfacing on Structural Steel with Titanium Carbide

Hardfacing is carried out to enhance the hardness of the surface of a substrate by depositing a hard and wear resistance filler metal. It is a more cost-effective to construct it out of regular steel and then coat the important layer of welded metal that can ensure the required hardness at the surface. A hardfacing system was developed by employing Robotic Gas Metal Arc Welding for the hardfacing of Stellite 21 on the Mild steel substate. The various components of the hardfacing system and the detailed procedure of hardfacing including the programming the robot, setting the process parameters, conducting the experiments as per Taguchi L9 array and the measurement of hardness were explained. Hardfacing trial 5 gave the maximum hardfacing deposit hardness of 499 Hv.

https://scientifictemper.com/index.php/tst/article/download/412/381

Satellite hardfacing of mild steel using robotic mig welding

In recent years, hardfacing processes have developed rapidly and are now applied in numerous industries. The biggest difference between welding a joint and hardfacing is dilution. The composition and properties of hardfacing are strongly influenced by the dilution obtained. Control of dilution is very important in hardfacing, where low dilution is typically desirable. This is obtained by proper selection of process parameters such as welding current, open circuit voltage, travel speed, nozzle-to-work distance, shielding gas, gas flow rate, and welding position. This paper presents about an experimental study carried out to analyze the effect of various parameters of plasma transferred arc welding in tungsten carbide hardfacing of 316L stainless steel plates on bead geometry. The experiments were conducted based on five-factor five level central composite rotatable design. Mathematical model were developed to predict bead width, height of reinforcement, depth of penetration and percentage of dilution. The developed mathematical models have been checked for their adequacy and significance. These mathematical models are very useful for optimizing the process parameters. The effects of process parameters on bead geometry have been presented in graphical form, which helps in selecting welding process parameters to achieve the desired bead geometry quickly.

Effects of Plasma Transferred Arc Welding Parameters on Bead Geometry in Tungsten Carbide Hardfacing

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Effects of Plasma Transferred Arc Welding Parameters on Bead Geometry in Tungsten Carbide Hardfacing