Journal 11
Journal 11
PAPER
Abstract
Cold Metal Transfer (CMT) welding was used to join SS304L plates using SS308L MIG wire. The
effects of current, the distance between nozzle and tip, welding speed on strength, hardness and
surface roughness of welded zone in the CMT process using response surface methodology were
investigated in the present study. The outcomes show that current is having a significant effect on the
outputs. Also, current interacting with weld speed is showing its mark on the output variables like
tensile strength, hardness and surface roughness. Finally, optimal results are found and the
experimental values are in coincidence with the predicted values.
1. Introduction
Short-circuiting transfer based and a modified form of MIG welding process by name Cold metal transfer
welding process. This was developed in the early 2000s by an Austrian company Fronius. The only difference
between MIG/MAG and CMT is the mechanical droplet cutting method [1]. A method for controlling the
material deposition which leads to less thermal input is used in the CMT welding process [2]. This less heat input
leads to a reduction in solidification defects [3]. An important feature of the CMT process is a short circuit with
low current leading to low heat input.
Low heat input results in inadequate melting time for enough materials, which causes a low volume weld
pool with quick freezing as a result. This affects the dendritic structure and regulates the development of
intermetallic layers [4]. It is proposed that a further decrease in weld heat input can be achieved by combining
welding with a magnetic field for joining dissimilar metals [5].
The short circuit in CMT occurs in a controlled manner with stability. This confirms the stable and
controlled deposition in CMT welding. Desired control of heat input, high welding speed, narrower heat
affected zone etc are the advantages offered by the CMT technique compared to other joining processes [6].
There are four phases in the CMT welding process i.e., two hot phases and two cold phases. The sequence of
those is hot, cold, hot, cold [7].
During the first hot phase, i.e., arcing period, filler metal moves to the weld pool. In the cold phase 1, filler
metal drench in the weld pool, the arc quench leads to the lowering of welding current. the hot phase 2, wire
droplet detachment is assisted by wire backward movement through the short circuit and the current of it is
maintained little. In the last stage, there is a reversal in wire motion.
Researchers studied Cold Metal Transfer welding with the characteristics of arc, transfer of droplet,
weldment properties and microstructure [8].
To improve the quality, flexibility and productivity of the welding performance, process parameter
optimization is necessary. Transient numerical model was developed to analyse the TIG - CMT hybrid welding
Levels
Process parameter Units
−1 1
and further increase the potentiality of weld formation for cladding Inconel [9]. Mathematical models were
developed to show the effects of input parameters on the quality of weldment [10]. Researchers paid attention to
the recognition of the best parametric combination in CMT welding of Al alloys [11]. Effects of Wire feed speed
and Arc length correction on the micro, macrostrucutres and wear performance on Aluminium cladding using
CMT were investigated [12]. Multi-parameter optimization techniques were used to identify the weld quality in
terms of reinforcement of welded joint, width of the bead, penetration depth i.e., DOP, width of the heat affected
zone i.e., HAZ [13]. Also, various mechanical properties were optimized in CMT welding using multi-parameter
optimisation [14]. Various mathematical models were developed in welding using response surface
methodology techniques to predict the weld quality [15]. Full factorial central composite face-cantered design
(CCFCD) was utilized to optimize the tensile properties, microhardness and residual stresses in CMT
welding [16].
CMT welding of Al 6061-T6 and galvanized steel for automobile applications was done with the aid of OA,
ANOVA analysis and optimal parametrs are determined [17]. The desirability functions, design of experiments,
and polynomial models are all used in the RSM approach to obtain the ideal working point with the least trials
[18]. DoE is a group of methods for defining a series of tests whose outcomes depend on the input variables.
Fisher created it in the 1920s, and it was first used to examine how fertilisers affected various crops [19].
Currently, both experimentally and through simulation [20–23]. DOE are implemented to perform
optimizations for both multi and single objectives. Box Behnken design was developed for single, multi
parameter optimisation for machining of Incoloy 800H using Wire EDM [24]. Taguchi optimisation was done
with the aid of ANOVA for various parameters in Magnetic assisted abrasive machining [25].
DoE evaluates the factors’ numbers, combinations, randomization, replication, and blocking to confidently
analyse cause-and-effect correlations. Since the trials in this instance are finite element studies, randomization,
replication, and blocking are not required.
In this work, Response surface methodology is used to identify the process parameters which yield better
quality in weldments in terms of weld strength, hardness and surface roughness along with mathematical model
development.
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1 95 10 4.03
2 105 10 4.03
3 105 6 5.817
4 108.409 8 4.9235
5 100 8 3.42082
6 95 10 5.817
7 100 8 4.9235
8 105 6 4.03
9 91.591 8 4.9235
10 100 4.63641 4.9235
11 95 6 5.817
12 100 8 4.9235
13 100 11.3636 4.9235
14 105 10 5.817
15 100 8 4.9235
16 100 8 4.9235
17 100 8 6.42618
18 100 8 4.9235
19 100 8 4.9235
20 95 6 4.03
2.2. Materials
Austenitic steels can be welded through all sorts of welding techniques. Among those SS304L has versatile
applications in industry, and domestic fields and attractive features viz high resistance to corrosion, ease of
fabrication, and outstanding formability. SS304L plates with a thickness of 5 mm are taken. They are butt welded
using SS308L wire using CMT welding. These are shown in figure 1.
Chemical composition and Properties of the SS304L and MIG wire are mentioned in table 3.
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Eng. Res. Express 5 (2023) 015076 S B Ainapurapu et al
Chemical composition
(Weight %)
Element
SS304L SS308L
108.409 Amp, 91.591 Amp, 5.817mm/sec, 4.9235mm/sec etc are set up to the nearest values like 108 amp, 92
Amp, etc. The CMT setup used is shown the figure 2. Shielding gas used is Argon and CO2 mixture with a flow
rate of 18 Litres per minute.Metallurgical evidence for the Weld bead of one joint is shown in figure 3.
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Figure 4. (a) Tensile testing specimen (b) Micro Tensile Testing Machine. (c) Rockwell Hardness tester (d), (e) Hardness Testing areas
(f) Surface Roughness Tester.
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According to the R2 statistic, the fitted model accounts for 99.76% of the variation in tensile strength. The
modified R2 value is 99.66%, making it more appropriate for comparing models with various numbers of
independent variables. Adequate precision measures the signal-to- noise ratio and it should be more than 4. In
this case, it is 117.0552 indicating an adequate signal.
Table 5, 6 shows the ANOVA and fit statistics model for Tensile strength.
3.1.1.2. Hardness
To gain maximum hardness at the welded zone for the given inputs following analysis is done.
Following is the table of ANOVA to get the significant values of Hardness at the welded zone.
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Eng. Res. Express 5 (2023) 015076 S B Ainapurapu et al
For Hardness, Current(A), Current, Travel speed (AC) interaction, Current, and Contact Tip to work
distance (AB) interaction are significant. Here non-significant factors are CTWD and weld speed.
Here predicted R2 is negative indicating overall mean will be the better predictor for the response. Adequate
precision of 12.7945 indicates that the model is having adequate signal.
ANOVA and fit statistics model for Hardness is shown in tables 7, 8.
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Eng. Res. Express 5 (2023) 015076 S B Ainapurapu et al
Sum of Mean
Source squares df square F-value p-value
3.1.2.2. Hardness
Equation 4 is the empirical formula derived for the Hardness at the welded zone.
Hardness = 62.98450 - 0.35755(A)
+ 42.46121(B) - 69.788(C ) - 0.377500(AB)
+ 0.777840(AC ) - 0.853386(BC ) (4)
Figure 6 shows the shows a scatter plot between the fitted and experimental Hardness values and a
perturbation plot to show the influence of all single variables at the central point of design space.
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Eng. Res. Express 5 (2023) 015076 S B Ainapurapu et al
Figure 6 shows the actual versus predicted plot and perturbation plots of Hardness.
Figure 7 shows the actual versus predicted plot and perturbation plots of Surface Roughness
In the left side graph for hardness scattered points are far away from the 45° lines indicating that
experimental values are deviating from predicted values. The perturbation graph shows that output is
responding the same for both B, and C factors. But there is a vast increase in Hardness for Factor A.
Surface roughness graph of predicted versus actual values shows that scattered points are near to 45° lines
indicating that experimental values are in accordance with predicted values. The perturbation graph reveals that
output is decreasing for B, while it is increasing with A and C factors.
3.1.3.2. Hardness
Maximum Hardness is going to be observed in the red and yellow colour zone in the contour.
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Eng. Res. Express 5 (2023) 015076 S B Ainapurapu et al
Figure 7. Predicted versus actual plot and perturbation graphs for surface roughness.
3.2. Optimisation
3.2.1. Tensile strength
After observing the individual effects, interaction graphs and response graphs, Current (A), Contact Tip to work
Distance(B), Weld Speed (C) and their interactions are having their effect on the Tensile Strength of the welded
zone. Here Current, CTWD shows a nominal impact whereas Speed is having a considerable effect and is
inversely proportional. In the interactions graph of AC, more curvature is observed revealing that more amount
affects the Tensile strength.
3.2.2. Hardness
For getting the maximum Hardness at the welded zone Current,Contact tip to work distance and Speed shows
direct nominal impact. The interaction of current and weld speed has more impact.
4. Conclusions
Effects of input factors viz Current, contact tip to work distance (CTWD) and Weld speed on the weldment’s
Strength, Hardness and surface roughness after the Cold Metal Transfer welding of SS304L plates using SS308L
using Response Surface Methodology was investigated. Following conclusions are drawn in this experiment and
analysis.
1. Among all the input parameters Current is having a significant effect on the output responses.
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Eng. Res. Express 5 (2023) 015076 S B Ainapurapu et al
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Figure 10. Contour plots and response graphs for surface roughness.
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Parameter Limits
Nozzle to tip
Inputs Current distance Weld speed
2. Interaction of Current and Weld speed showing the maximum effect on the most important mechanical
properties i.e. Tensile strength, Hardness of the welded zone.
3. If the surface roughness is taken as an important factor nozzle tip distance and its interaction with Current
has to be considered.
4. Finally, a current of 103 Amperes, 8 mm of the nozzle to tip distance and 4.8 mm s−1 are the optimal
values which are yielding a tensile strength of 390 MPa, 80 BHN hardness and 22 microns of surface
roughness
Further this work may be extended to optimise other input parameters to achieve better mechanical properties
and also using various machine learning algorithms.
All data that support the findings of this study are included within the article (and any supplementary files).
ORCID iDs
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