CONTENTS

Declaration i
Certificate ii
Acknowledgement iii
Abstract iv
List of Figures v
Chapter 1. Introduction.
1.1 About the industry 01
1.2 Characteristics of MS alloy. 03
1.2.1 Composition of MS alloy 04
1.2.2 Physical and Mechanical properties of MS alloy 05
1.2.3 Unique properties of MS alloy 06
1.2.4 Application of MS alloy 07
1.2.5 Problems in fusion welding of MS alloy
and causes of such problems. 09
1.3 Welding of MS alloy by arc welding process. 10
1.4 GMAW Process. 12
1.4.1 GMAW Equipment parts. 14
1.4.2 GMAW Applications 16
Chapter 2. Literature review.
2.1 Effect of GMAW process parameters on mechanical properties 19
of welded joints.
2.2 Techniques for optimizing the process parameters. 21
2.3 Effect of filler material composition on mechanical properties 22
of MS alloy welded joints.
2.4 Effect of heat treatment to the MS alloy welded joints. 22
2.5 Summary of literature review. 25
Chapter 3. Objective of the present work 27
Chapter 4. Experimental investigation
4.1 Selecting the work material and its Specification. 29
4.2 Selection and development of new filler material. 30
4.3 Experimental set up (GMAW) and procedure. 32
4.3.1 Specification of (GMAW) experimental setup. 33
 4.3.2 Joint Design and Preparation. 34
4.3.3 Working of (GMAW) experimental setup. 35
4.3.4 Experimental procedure. 38
4.3.5 Selection of GMAW process parameters and responses. 39
4.3.6 Determining the range of selected GMAW process parameters. 40
4.4 Tensile Testing. 43
4.5 Bending test and Hardness testing 50
4.5 Metallography study of welded joints. 53
Chapter 5. Experimental results and discussion
5.1 Effect of SS containing filler wire on mechanical 56
properties of welded joints.
5.1.1 Description on preliminary investigation of GMAW. 58
(With SS filler material)
5.1.2 Effect of ss filler material composition on mechanical properties. 60

5.4 Effects of Using Stainless Steel (SS) Filler Wire on Mechanical Properties 64
of Welded Joints

Chapter 6. Conclusion. 68
Test Report
Reference 71
 DECLARATION
I hereby declare that the project report titled “The Effect of Stainless-Steel Filler Wire on
the Properties of Mild Steel Welded Joints” submitted to KLS VDIT is a record of original
work carried out by me under the guidance of Dr.K.S. S Pujari. The project outcomes and
findings are based on independent research and experimentation. Every effort has been made
to ensure the accuracy and reliability of the data, as well as the relevance of the conclusions
drawn.

Furthermore, I extend my sincere gratitude to my institution, faculty, and peers who provided
invaluable support and resources for the successful completion of this project. This report is a
testament to the knowledge and experience gained during this academic endeavour.
 ACKNOWLEDGMENT
I am profoundly grateful to KLS VDIT for providing me the opportunity to undertake this
project titled “The Effect of Stainless-Steel Filler Wire on the Properties of Mild Steel
Welded Joints.”

First and foremost, I would like to express my heartfelt gratitude to my guide, Dr K.S. Pujari
for their invaluable guidance, constructive feedback, and constant support throughout this
project. Their expertise and insights have been instrumental in shaping the direction and
outcomes of this study.

I extend my sincere thanks to the Mechanical department faculty and staff for their
unwavering encouragement and for equipping me with the necessary resources and facilities
to conduct this research effectively.

I am also deeply thankful to my peers and colleagues, whose thought-provoking discussions

and shared knowledge enriched my learning experience.
 Abstract
This report evaluates the mechanical performance of mild steel (MS) welded joints using
three welding techniques: normal arc welding, MIG welding with standard filler wire, and
MIG welding with stainless steel (SS) filler wire. The investigation focuses on understanding
the impact of these methods on joint strength, with a particular emphasis on tensile strength,
bending, and hardness tests. The study also examines the role of welding parameters, filler
material composition, and heat treatment in influencing joint properties.

Experimental findings highlight the differences in tensile strength and other mechanical
properties between the techniques. MIG welding with SS filler wire demonstrated improved
mechanical strength due to additional alloying elements like chromium and nickel, which
enhance ductility and corrosion resistance. The integration of Gas Metal Arc Welding
(GMAW) process parameters, including voltage, current, wire feed speed, and shielding gas
flow rate, was crucial for optimizing weld quality.

This research provides actionable insights for industries requiring robust welded joints,
facilitating the selection of optimal welding techniques and materials for specific structural
and industrial applications. The results also emphasize the significance of controlled welding
conditions and filler material compatibility in achieving superior joint performance.
 List of Figures
Fig No Name Page No
1.1 Agril industry 1
1.2 Heavy Wheel Disc 2
1.3 Standard Wheel Disc 2
1.4 Automobile Industry 7
1.5 Agriculture and Industrial Equipment 8
1.6 Mig Welding setup 11
2.1 MS With Mig Welding Specimen 20
2.2 Heat treatment 22
4.1 Arc Welding MS specimen 26
4.2 Mig welding Machine 29
4.3 MS Arc Welding Butt Joint 31
4.4 Grinding machine 31
4.5 Mig welding Gun 32
4.6 Tensile testing setup 40
4.7 Mig Welding with SS Filler Wire 41
Specimen
4.8 Load Vs Displacement Graph 41
4.9 Mig Welding Specimen 42
4.10 Load Vs Displacement Graph 42
4.11 Plain Test Specimen 43
4.12 Load Vs Displacement Graph 43
4.13 Arc Welding Test Specimen 44
4.14 Load Vs Displacement Graph 44
4.15 Bending test setup 47
4.16 MS Specimens After Bending test 47
4.17 Rockwell Hardness Test 48
4.18 Rockwell Hardness Test Specimen 49
4.19 Metallography setup 50
4.20 Plain specimen 51
4.21 Mig with SS Filler Wire Welding 51
Specimen
4.22 Arc welding Specimen 52
4.23 Mig welding Specimen 52
5.1 Mig welding process 53
6.1 Project Work at Agril Industries 64

List of Tables
Table No Name Page No
1 Tensile test Result 49
2 Bending Test Result 51
3 Hardness test Result 52