Abstract

Metal active Gas (MAG) welding is one of the widely used techniques for joining ferrous and non-ferrous metals. In this experiment Design of Experiment method was used. Investigation of MAG welding parameter optimization for good penetration and surface quality is very important to improve the technology of MAG welding application. The aims of this thesis was examine effects of eight MAG welding parameters on Mild Steel specimens which have dimension 150 mm x 100 mm x thickens, by metal active gas. These welding parameters are amperage, arc voltage, welding speed, stick-out length, welding angle, shielding gas, material thickens were selected for the DOE based on the selection criteria for investigated depth of joint penetrations and welding porosity on butt joint.

By used the optimization tool the thesis deals with the input parameters of MAG welding and examines the interaction between welding parameters and its response. As the DOE indicated MAG welding parameters are the most important factors to control welding quality, productivity and failure cost. The Experiments was conducted based on taguchi and root cause analysis diagram. Root cause identification for quality and productivity related problems are key issues for manufacturing processes. The experimental work was conducted to optimize the input process parameters to get optimum welding quality. By used DOE each welding parameter their influence for porosity and joint penetration were investigated. Analysis and optimization of MAG welding parameters were conducted based on ANOVA and GA respectively.

Based on the optimized parameters welding porosity decrease by 3.92%, 3.34 %, 3% in flat, horizontal and vertical welding position respectively with maximum penetration of 4.61, 3.71, 3.21 mm, respectively of the welding position at the shielding gas of 12 L/min were found as the result of DOE indicated amount of shielding gas not affected by the welding position that’s way shielding gas of 12 L/min were led for the three welding positions.

Key point, MAG welding, DOE, root cause analysis, GA, ANOVA
Abstract

Metal active Gas (MAG) welding is one of the widely used techniques for joining ferrous and non-ferrous metals. In this experiment Design of Experiment method was used. Investigation of MAG welding parameter optimization for good penetration and surface quality is very important to improve the technology of MAG welding application. The aims of this thesis was examine effects of eight MAG welding parameters on Mild Steel specimens which have dimension 150 mm x 100 mm x thickens, by metal active gas. These welding parameters are amperage, arc voltage, welding speed, stick-out length, welding angle, shielding gas, material thickens were selected for the DOE based on the selection criteria for investigated depth of joint penetrations and welding porosity on butt joint.

By used the optimization tool the thesis deals with the input parameters of MAG welding and examines the interaction between welding parameters and its response. As the DOE indicated MAG welding parameters are the most important factors to control welding quality, productivity and failure cost. The Experiments was conducted based on taguchi and root cause analysis diagram. Root cause identification for quality and productivity related problems are key issues for manufacturing processes. The experimental work was conducted to optimize the input process parameters to get optimum welding quality. By used DOE each welding parameter their influence for porosity and joint penetration were investigated. Analysis and optimization of MAG welding parameters were conducted based on ANOVA and GA respectively.

Based on the optimized parameters welding porosity decrease by 3.92%, 3.34 %, 3% in flat, horizontal and vertical welding position respectively with maximum penetration of 4.61, 3.71, 3.21 mm, respectively of the welding position at the shielding gas of 12 L/min were found as the result of DOE indicated amount of shielding gas not affected by the welding position that’s way shielding gas of 12 L/min were led for the three welding positions.
Key point, MAG welding, DOE, root cause analysis, GA, ANOVA

GEBREMESKEL KAHSAY

Affiliation

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Analysis and Optimization of MAG welding Parameters Using Genetic Algorithm