UNIVERSITI TECHNOLOGY MALAYSIA

UNIVERSITI
FACULTI TECHNOLOGY MEKANIKAL
KEJURUTERAAN MALAYSIA

FACULTI KEJURUTERAAN MEKANIKAL

PROJEK SARJANA MUDA 1
(SMJ 4912)
PROJEK SARJANA MUDA 2
(SMJ 5924)
25 OCTOBER 2009

25 OCTOBER 2009
EVALUATION OF CARBON STEEL PLATE USING
SUBMERG ARC WELDING

• NAMA : ZAINAL ABIDDIN SHAH BIN MATTAR

• METRIC NO: SX045349MMD04

• I/C NO : 650419-04-5297

• SUPERVISOR: PM ZAINAL ABIDIN BIN AHMAD

 CONTENTS
INTRODUCTION

OBJECTIVE

SCOPE

METHODOLOGY

EXPERIMENTAL

RESULTS & ANALISIS

CONCLUSION & DISCUSSION

 INTRODUCTION

• Submerged Arc Welding (SAW) process performs with high

productivity coupled with satisfactory penetration, good
deposition rate, and smooth spatter free weld and has easy
weld control. SAW is preferred for high thickness metal
sheets / plates maximum
• Carbon steel plate has wide application. It extensively used
in heavy fabrication industries. Carbon steel A36 steel is a
standard steel alloy which has a density of 0.28 lb/in³
(7.8 g/cm³).
• A36 steel in plates, bars and shapes with a thickness of
less than 8 in (200 mm) has a minimum yield strength of
36,000 psi (250 MPa) and ultimate tensile strength of
58,000–80,000 psi (400–550 MPa)
 OBJECTIVE

To find out the optimal welding process

parameter of Submerge Arc Welding and
their interactions for four mechanical
performance characteristics such as
tensile, hardness and deposition rate on
carbon steel ASTM 36.
 SCOPE

• Experiment using Carbon steel plate A36 and the

specimen to be weld using Submerge Arc
Welding Machine
• Two range (lower level & upper level ) from four
parameter of submerge arc welding was decide
as a scope of testing.
• Orthogonal array for L8 (27) Taguchi design was
chosen
• Tensile test , Hardness test and deposition was
selected as mechanical properties testing.
 METHODOLOGY

o Taguchi method was selected as a design experiments.

This method use a special set of arrays called
Orthogonal arrays. Develop by Dr. Genichi Taguchi a
Japanese quality management consultant (Peace, G.S,
1993)

o This project will be conducted through the

experimental / testing using Submerge Arc Welding
Machine. (Model: Austcorp. Manufacturing – DC 1300 )

o The data from experiment will be analyze by MINITAB

which have statistical analysis.
 Start

Prepare specimens.
(Carbon Steel A36)

Submerge Arc welding machine setting. Four

parameter and 2 level of range was selected

Weld specimens using Taguchi method L8(27)

Mechanical
Properties Test

Tensile Test Hardness Test Deposition

Micro
Structure
Check Collect Data
Collect Data Collect Data

Analysis data using MINITAB method

Finish
 WORKING RANGE OF THE PROCESS
PARAMETER

Symbol Process Units Lower Level Upper Level

Parameter (1) (2)

A Arc Current Amp 400 500

B Arc Voltage Volt 26 30

C Welding Speed mm/sec 30 40

D Electrode Stick-out mm 19 25
 TAGUCHI DESIGN L8 (27 )

Exp.no . A B AxB C AxC BxC D

P1 1 1 1 1 1 1 1
P2 1 1 1 2 2 2 2
P3 1 2 2 1 1 2 2
P4 1 2 2 2 2 1 1
P5 2 1 2 1 2 1 2
P6 2 1 2 2 1 2 1
P7 2 2 1 1 2 2 1
P8 2 2 1 2 1 1 2
 EXPERIMENT TABLE

Specimen Tensile strength (Mpa) Micro Hardness (HV) Dilution (%)

ID Trial 1 Trial 2 Trial 1 Trial 2 Trial 1 Trial 2

P1 x1 x2 x1 x2 x1 x2

P2 x1 x2 x1 x2 x1 x2

P3 x1 x2 x1 x2 x1 x2

P4 x1 x2 x1 x2 x1 x2

P5 x1 x2 x1 x2 x1 x2

P6 x1 x2 x1 x2 x1 x2

P7 x1 x2 x1 x2 x1 x2

P8 x1 x2 x1 x2 x1 x2

Base metal x1 x2 x1 x2 x1 x2
SCHEME OF WELDING WITH RESPECT TO ROLLING
DIRECTION AND EXTRACTION OF TENSILE
SCHEMATIC OF WELD DESIGN (SIDE VIEW)
SCHEMATIC OF WELD DESIGN FOR TENSILE
SPECIMEN
SCHEMATIC OF HARDNESS WELD AREA
EXPERIMENT PROGRESS
EXPERIMENT PROGRESS
EXPERIMENT PROGRESS
EXPERIMENT PROGRESS
EXPERIMENT PROGRESS
TENSILE TEST DATA
TEST REPORT FOR TENSILE
HARDNESS TEST DATA
GRAPH :HARDNESS VERSUS WELD AREA
Hardness versus welding Area

250
specimen 1
V/ Hardness (500 gram)

200 specimen 2
specimen 3
150 specimen 4
specimen 5
100
specimen 6
specimen 7
50
specimen 8
0
Weld HAZ Base metal
centre
welding area
RESULT FOR DEPOSITION
 SAMPLE CALCULATION

• Deposition = Weight after weld – Weight before weld

• Process Time
• = 1819.35 - 1756
• 30
• = 2.111 gram/sec

• To convert gram/sec to kg/hour

• Therefore;

• 2.111 gram/sec × [1 kg/1000 gram] × [3600 sec / 1 hour]

• = 2.11 × 3600
• 1000

• = 7.602 kg/hour ( convert to kg/hour

FULL RESULTS
S/N RATIO FOR TENSILE
S/N RATIO FOR HARDNESS
S/N RATIO FOR DEPOSITION
 MICRO-STRUCTURE RESULTS

100um 100um

Specimen No.3 Specimen No.2

 GRAPH : MAIN EFFECT FOR
TENSILE

Main Effects Plot (data means) for Tensile

welding current welding voltage
54.0

53.5

53.0

52.5
Mean of Tensile

52.0
400 500 26 30
welding speed wire stick out
54.0

53.5

53.0

52.5

52.0
30 40 19 25
 GRAPH : MAIN EFFECT FOR
HARDNESS
Main Effects Plot (data means) for Hardness
welding current welding voltage
186.0
184.5

183.0
181.5
Mean of Hardness

180.0

400 500 26 30
welding speed wire stick out
186.0

184.5
183.0

181.5
180.0

30 40 19 25
 GRAPH : MAIN EFFECT FOR
DEPOSITION
Main Effects Plot (data means) for Deposite rate
welding current welding voltage
7.85

7.80
Mean of Deposite rate

7.75

7.70
400 500 26 30
welding speed wire stick out
7.85

7.80

7.75

7.70
30 40 19 25
 GRAPH :INTERATION RATIO
FOR TENSILE
Interaction Plot (data means) for SN ratios
Interaction Plot (data means) for SN ratios
34.7 C
B 30
35.0 26 40
30
34.6
34.8

34.6 34.5

SN ratios
SN ratios

34.4
34.4
34.2

34.3
34.0

33.8 34.2
400 500 400 500
A A

Signal-to-noise: Larger is better Signal-to-noise: Larger is better

AxB Interaction Plot (data means) for SN ratios

AxC
34.8 C
30
34.7 40

34.6

34.5
SN ratios

34.4

34.3

34.2

34.1

34.0
26
B
30 BxC
Signal-to-noise: Larger is better
 TENSILE ANALISIS

From the analysis data we find out the maximum value of

tensile can be achieved if control factor are set at B2 C1 A2 D1
 HARDNESS ANALISIS

From the analysis data we find out the maximum value of hardness
can be achieved if control factor are set at C2 D1 B1 A2
 DEPOSITION ANALISIS

From the analysis data we find out the maximum value of deposition
can be achieved if control factor are set at C2 A1 B1 D1
 SUMARRY OF RESULTS

• Maximum tensile : Arc current 500 amps; Arc voltage 30 volt; welding speed 30
mm/sec; electrode sickout is 19 mm.

• Maximum hardness :Arc current 500 amps; Arc voltage 26 volt; welding speed
40 mm/sec; electrode sickout 19 mm.

• Maximum deposition :Arc current 400 amps; Arc voltage 26 volt; welding
speed 40 mm/sec; electrode sickout 19 mm
 DISCUSION

• Taguchi’s Method design on experiment is the best

solution to get optimum welding-process-parameter
and their interaction.

• From the experiment and testing data, its will show to

us the optimal levels and their interaction of the
factors for the mechanical properties.

• It was observed that the performance characteristics

of the SAW process, such as deposition rate, dilution
and hardness, are improved together by using the
method proposed in this study.
 CONCLUSION

• Factors such as arc current, arc voltage and

welding speed and their interactions play a
significant role in the SAW process.

• From the Taguchi’s experimental design we

can get a optimum welding process parameter
and the combinations for each of the
performance criteria by maximization of
deposition rate, minimization of dilution and
maximization of hardness.
Thank You