A review on Parametric Optimization of Submerged arc welding process

IJSRD - International Journal for Scientific Research & Development| Vol. 3, Issue 10, 2015 | ISSN (online): 2321-0613
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A Review on Parametric Optimization of Submerged Arc Welding
Process
Harsh H. Patel1
Yagnang R. Pandya2
Rakesh B. Prajapati3
1,2
Department of Mechanical Engineering
1,2
AIT 3
Sal College of Engineering
Abstract— Submerged arc welding is preferable more its
inherent qualities such as Higher deposition rate, deeper
penetration, control of variables, high quality, smooth finish.
The bead geometry shows the quality of weld which is
depends on input process parameters. The present work
gives review of the effect of these Input parameters on weld
bead geometry. Selection of process parameters has great
influence on the quality of a welded connection. To
automate a welding process, which is the present trend in
any fabrication industry. It is also important that
mathematical models have to be developed to relate the
process variables to the weld bead parameters. All the
welding processes are used with the aim of getting a welded
joint with the desires weld bead geometry and excellent
mechanical properties with a efficient quality welded joint at
a relatively low cost with high productivity. Optimization
designs concentrate on only one or two parameters, but in
very more depth to gain a precise understanding of
relationships between parameters.
Key words: Submerged arc welding (SAW), process
parameters, Weld bead geometry, Design of experiments,
parametric optimization
I. INTRODUCTION
Submerged arc welding is basically an arc welding process.
Submerged arc welding is the best efficient welding process
for fabrication industries. In submerged arc welding process
Coalescence is produced by heating application with an
electric arc and arc set up model between a bare metal
electrode and the work piece. The basic components of
submerged arc welding are power source, flux hopper,
electrode wire, granular flux, control panel, welding gun. As
per the name given arc is merged beneath a layer of granular
flux in this type of welding. The power source can be a
transformer for AC welding or a rectifier (motor generator)
for DC welding. The consumables are a bare, possibly
coppered, continuous electrode and a granular welding flux
fed to the joint by a hose from a flux hopper. The arc burns
in a cavity filled gases like CO2, CO and etc. formed by
breakdown on the total flux and metal fumes. Use of these
technology and social implications in the national
prospective. The effective process parameters include Arc
current, Arc voltage, Welding speed, nozzle to plate
distance, Wire feed rate and flux basicity index. The present
work gives review of the effect of these parameters on weld
bead geometry and flux consumption. Submerged arc
welding is one of the oldest automatic welding process
during 1930 s and it contributes to approximately 10% of
the total welding needs the world. It is generally used for
welding of low carbon steels, high strength low alloy steels,
nickel base alloys and stainless steels. Apart from
coalescence this process can be used for cladding
applications to increase corrosion resistance and wear
resistance on the surfaces. Weld produced are uniform,
ductile, sound and good impact resistance.
Fig. 1: Submerged Arc Welding Machine
II. LITERATURE REVIEW
Serdar Karaoglua et al. [1] has investigated that the
sensitivity analysis of Input parameters and fine tuning
requirements of the Input parameters for optimum weld
bead geometry. Changeable process Input parameters such
as welding current, welding voltage and welding speed are
used as Input parameters in this study. The output
parameters are width, height and penetration of the weld
bead. In this Experimental part of the study is based on three
level factorial design of three process parameters. In order to
investigate the effects of input (process) parameters on
output parameters, which determine the weld bead
geometry, a mathematical model is constructed by using
multiple curvilinear regression analysis. After carrying out a
sensitivity analysis using developed empirical equations,
relative effects of input parameters on output parameters are
obtained. Effects of all three design parameters on the bead
width and bead height show that even small changes in these
Input parameters plays an important role in the quality of
welding operation. The result also shows that the penetration
is almost non-sensitive to the variations in voltage and
speed. It was conclude that Bead width is more sensitive to
voltage and speed variations than that of bead height and
penetration. All three Input process parameters have effects
in determining the bead height. In order to decrease the bead
height, higher values of voltage and speed can be
considered. Current is the most important parameter in
determining the penetration. Voltage and speed cannot be
effectively used to control penetration.
N. Murugana et.al. [2] has investigated that it is
very essential that mathematical models have to be
enveloped to relate the process variables to the weld bead
parameters or output parameters. Because of its high
productivity, smooth finish, high reliability and deep
penetration submerged arc welding (SAW) has become a

A Review on Parametric Optimization of Submerged Arc Welding Process
(IJSRD/Vol. 3/Issue 10/2015/158)
natural choice in industries for fabrication, especially for
welding of pipes. In this study they selected welding speed,
Arc voltage, Wire feed rate, and nozzle to plate distance as
input parameters and responses are bead width,
reinforcement and penetration. Mathematical models have
been developed for submerged arc welding (SAW) of pipes
using five level factorial techniques to predict three critical
dimensions of the weld bead geometry and shape
relationships. The models developed have been checked for
their adequacy and significance by using the F-test and the t-
test, respectively. Main and interaction effects of the input
process parameters on bead geometry and shape factors are
presented in graphical form and using which not only the
prediction of important weld bead dimensions and shape
relationships but also the controlling of the weld bead
quality by selecting appropriate process parameter values
are possible. On experimentation and investigation it was
concluded that out of the four process variables considered,
wire feed rate had a significant positive effect but welding
speed had an appreciable negative effect on most of the
important bead parameters, Reinforcement form factor,
penetration size factor, penetration and bead width all
increased with the increase in wire feed rate for all values of
welding speed but this increasing rate of the bead
parameters with the increase in wire feed rate(F), gradually
decreased with the increase in welding speed(S).
Y.S. Tarng et al. [3] has studied and investigated
that the use of the grey-based Taguchi method to obtain the
submerged arc welding (SAW) process parameters with
consideration of multiple performance characteristics has
been studied in this paper. A grey relational analysis of the
S/N ratios can convert the optimization of the multiple
performance characteristics into the optimization of a single
performance characteristic known as the grey relational
grade. A grey relational grade obtained from the grey
relational analysis is used as the performance characteristic
in the Taguchi design of experiment method. In this paper
arc current, welding speed, arc voltage, preheat temperature
and electrode stick out are use as input parameters and
responses are deposition rate, dilution and hardness. Then,
optimal process parameters are determined by using the
parameter design proposed by the Taguchi method.
Experimental results have shown that optimal submerged
arc welding (SAW) process parameters in hardfacing can be
determined effectively so as to improving multiple weld
qualities through this new approach. On experimentation
and investigation it was concluded that arc current, welding
speed, and electrode stick-out are the significant welding
process parameters for affecting the multiple performance
Characteristics. It is also shown that the performance
characteristics of the submerged arc welding (SAW) process
such as Deposition rate, dilution, and hardness are improved
together by using the method proposed by this study.
J. Edwin Raja Dhas et al. [4] has investigated that
the effect of weld input parameters such as welding current,
welding speed, electrode stick out and welding current on
geometry of weld bead. A relationship between them is
thought to be complicated because of the non-linear
characteristics. In this paper trial-and-error methods to
obtain optimal conditions incur considerable time and cost.
In order to overcome these problems, non-traditional
methods have been suggested. Bead-on-plate Welds were
carried out on mild steel plates using semi-automatic
submerged arc welding (SAW) machine. Data were
collected as per taguchi’s design of experiments and
regression analysis was carried out to establish input–output
relationships of the process. By this relationship, an attempt
was made to minimize weld bead width which is a good
indicator of bead geometry, using optimization procedures
based on the genetic algorithm (GA) and particle swarm
optimization (PSO) algorithm to obtain optimal weld
parameters. On Experimentation and investigation it was
concluded that the developed PSO algorithm is a powerful
tool in experimental welding optimization, even when
experimenter does not have to model the process. These
tools find a good scope in the welding shop floor
environment to set the initial process parameter for the weld.
V. Gunaraj et al. [5] has studied and investigated
that the use of response surface methodology(RSM) by
designing a four-factor five-level central composite rotatable
design matrix with full replication for planning, conduction,
execution and development of mathematical models. These
are important not only for predicting the weld bead quality
but also for selecting optimum process parameters for
achieving the desired quality and process optimization. This
paper use input parameter as the open-circuit voltage (V),
the wire feed rate (F), the welding speed (S) and the nozzle-
to-plate distance (N), as input parameter and the penetration
(P), the reinforcement (R), the width (W) and the percentage
dilution (D) are as output parameters. This study used IS
2062 as base material. Response surface methodology
(RSM) is a important technique to determine and represent
the cause and effect relationship between true mean
responses and input control variables influencing the
responses as a two or three dimensional hyper surface.
Submerged arc welding (SAW) is used mostly in industry to
join metals in the manufacture of pipes of different length
and diameters. The main problem faced in the manufacture
of pipes by the submerged arc welding (SAW) process is the
selection of the optimum combination of input parameters
for achievement of the required qualities of weld. This
problem can be solved by the development of mathematical
models through effective and strategic planning and the
execution of experiments by response surface methodology
(RSM). On Experimentation and investigation it was
concluded that all of the responses viz. penetration (P),
reinforcement (R), bead width (W), and dilution (D)
decrease with increase in welding speed. As the nozzle-to-
plate distance increases, penetration (P), width (W), and
dilution (D) decrease, but Reinforcement(R) increases. An
increase in the wire feed rate results in an increase in
penetration (P), reinforcement (R), and dilution (D), but
width (W) remains unaltered.
D.V. Kiran.et al. [6] has investigated that detailed
experimental study on the influence of leading wire current,
welding speed, trailing wire current pulses on the weld bead
dimensions and mechanical properties in singlepass tandem
submerged welding of a typical high strength low alloy
(HSLA) steel. This study use current, voltage and welding
speed as input parameter and weld beds width,
reinforcement and cooling rate as responses. Two-wire
tandem submerged arc welding process include
simultaneous depositions from two electrode wires with the
leading wire generally connected to a DC power source and

A Review on Parametric Optimization of Submerged Arc Welding Process
(IJSRD/Vol. 3/Issue 10/2015/158)
the trailing wire connected to a pulsed AC power source.
The weld bead profile and mechanical properties in the
tandem submerged welding are significantly affected by the
leading and trailing wire current transients and the welding
Speed. The experimental results show that the final weld
bead width and reinforcement height are primarily
influenced by the trailing wire current while the penetration
is influenced by the leading wire current with the other
conditions remaining constant. Increase in trailing wire
current pulses enhance the weld pool size that tends to
reduce the cooling rate, inhibit acicular ferrite phases in
weld microstructure and result in poor mechanical
properties.
Shahnwaz Alamet al. [7] has investigate that two
level full factorial a technique has been used for experiment
design. Multiple regression analysis has been used to
develop a mathematical model to predict weld width using a
single wire Submerged arc welding depositing bead-on-plate
welds on 12mm plate. This investigation uses arc voltages,
current, welding speed, wires feed rate and nozzle-to-plate
distance as process parameters and AISI 1018 as base
material. Adequacy and significance of the model has been
checked by using analysis of variance, F-test and t-test
respectively. Main and interaction effects of process
variables on weld-width have been graphically presented.
Experiments have been performed to compare the results
obtained with the corresponding predicted values. The
models developed have been found to be adequate with a
confidence level 95%.Weld width has been found to
increase with increase in voltage, current and wire feed rate
and decreases with increase in welding speed and nozzle-to-
plate distance. Cross validation test fulfills the validity of
the model developed. On Experimentation and investigation
it was concluded that Weld width rapidly increases with
voltage, slowly increases with current and wire feed rate and
decreases with welding speed and nozzle to plate distance.
Pranesh B. Bamankar et al. [8] has investigate that
controlling metal transfer modes in submerged arc welding
(SAW) process is necessary to high quality welding
procedures. Quality has now become an important issue in
today’s manufacturing world. Experiments are conducted
using submerged arc process parameters viz. welding
current, welding speed (trolley speed) and arc voltage on
mild steel of 12 mm thickness, to study the effect of these
parameters on penetration depth. The experiments are
designed using Taguchi method (with Taguchi L9
orthogonal array) considering three factors and three levels.
On Experimentation and investigation it was concluded that
Current is predominant factor affect the bead width. Bead
width almost linearly increases with arc voltage and current
and decreases, with welding speed.
III. CONCLUDING REMARKS
On the basis of literature survey conclude that many
researchers have worked on different type of material by
using different type of parameters like arc current, arc
voltage, welding speed, nozzle to plate distance, basicity
index, pre heat temperature and etc. And effect of these
parameters was studied on various materials like IS 2062
steel plate, HSLA steel, AISI 1018 low/mild carbon steel
and etc. and its effect on output parameters like weld bead
width, bead height, penetration and etc. by using different
types of design of experiment techniques such as taguchi,
response surface methodology and full factorial design. In
most of the works welding current, arc voltage, welding
speed, nozzle to plate distance and wire feed rate are
considering for predicting and optimizing the weld bead
geometry. However certain the other parameters such as
wire diameter, welding gun Angle, flux feed rate, preheat
Temperature are not concentrated much especially.
- Some researchers conclude that the arc Current is the
most important parameter in determining the
penetration. Penetration is almost non-sensitive to
variations in voltage and speed.
- Bead width is more sensitive to voltage and speed
variations than that of all three process parameters
have effects in determining the bead height.
- Penetration, width, penetration size factor and
reinforcement form factor all increased with the
increase in wire feed rate for all values of welding
speed but this increasing rate of the bead parameters
with the increase in wire feed rate (F) gradually
decreased with the increase in welding speed(S).
REFERENCES
[1] Serdar Karaoglu, Abdullah Secgin,” Sensitivity
analysis of submerged arc welding process parameters”
journal of materials processing technology 202 (2008)
500–507, October 2007.
[2] N. Murugan, V. Gunaraj,” Prediction and control of
weld bead geometry and shape relationships in
submerged arc welding of pipes” Journal of Materials
Processing Technology 168 (2005) 478–487, 2005.
[3] Y.S. Tarng, S.C. Juang, C.H. Chang , “The use of
grey-based Taguchi methods to determine submerged
arc welding process parameters in hardfacing”, Journal
of Materials Processing Technology 128 (2002) 1–
6,2002.
[4] J. Edwin Raja Dhas, S. Kumanan, “Optimization of
parameters of submerged arc weld using non-
conventional Techniques” Applied Soft Computing 11
(2011) 5198–5204, May 2011.
[5] V. Gunaraj, N. Murugan,” Application of response
surface methodology for predicting weld Bead quality
in submerged arc welding of pipes”, Journal of
Materials Processing Technology 88 (1999) 266–275,
1999.
[6] D.V. Kiran, B. Basu , A. De , “Influence of process
variables on weld bead quality in two wire tandem
submerged arc welding of HSLA steel”, Journal of
Materials Processing Technology 212 (2012) 2041–
2050, May 2012.
[7] Shahnwaz Alam, Mohd.Ibrahim Khan, “Prediction of
the Effect of Submerged Arc Welding Process
Parameters on Weld Bead Width for MS”,
International Journal of Engineering and Innovative
Technology (IJEIT) Volume 1, Issue 5, May 2012.
[8] Pranesh B. Bamankar, Dr. S.M. Sawant, “Study of the
effect of process parameters on depth of penetration
and bead width in saw (submerged arc welding)
process”, International Journal of Advanced
Engineering Research and Studies E-ISSN2249–8974,
IJAERS/Vol. II/ Issue III/April-June, 2013.

A review on Parametric Optimization of Submerged arc welding process

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A review on Parametric Optimization of Submerged arc welding process