Investigating the effect of manual metal arc welding parameters on tensile strength for the welded heterogeneous steel plates
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Date
2023-08
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Kampala International University
Abstract
Welding describes a joining process by which two metal workpieces are joined together to form a joint with application of heat or pressure or a combination of both heat and pressure. Arc welding represents the class of welding processes which involve meting base metals at contacting surfaces to create a joint. Manual metal arc welding (MMAW), also known as stick welding, is the most popular arc welding method that uses a consumable flux electrode to generate an electric arc that fuses the base metal. Advancement in welding technology necessitates joining heterogeneous metals of low and high-carbon steel grades. In this study, AISI1018 low and AIS4340 medium carbon steels are welded using Manual Metal Arc Welding method. AISI1018 is a low-carbon steel known for its good weldability and moderate strength, commonly used in applications that require parts with excellent machinabilities and strength like fabrication of metallic doors, window grills. AISI4340 on the other side is a medium carbon steel that offers considerable strength and appreciable resistance to corrosion which makes it suitable for applications such as transmission shafts, gears and pressure vessels. However, AISI4340 welding yields high spatter, associated with porosity, incomplete fusion, and shallow penetration defects. This research focuses on investigating the influence of various manual metal arc welding parameters such as welding current, electrode angle, and weld orientation on the tensile strength of welded heterogeneous steel plates. Experimental variations of welding current, electrode position, and weld orientation MMAW input parameters were essential for the best weld quality. The experiments were planned using the Full Factorial design (FFD). Experimental results were analyzed using Minitab software version 21.3 (64-bit) with inbuilt ANOVA and regression analysis. The optimized condition was observed at tensile strength=101.90 MPa, with corresponding parameter values as follows: welding current=80A, electrode position=90o, and weld orientation=30o. Welding heterogeneous metals of low and high carbon steel grades resulted in increased tensile strength of weldments as the welding current increased. The weld bead height increased with an increase in welding current, electrode position, and weld orientation. By conducting a systematic analysis of welding current, electrode angle, and other relevant parameters, this study will provide valuable insights into the relationship between welding parameters and tensile strength for heterogeneous steel plate weldments.
Description
A Master research dissertation submitted to School of Engineering And Applied Sciences department of mechanical engineering in partial fulfillment of award of Master of Science in Mechanical Engineering (Mechanical Engineering General) of Kampala International University