Multi objective Optimization of TIG welding AA6061 alloy using response surface methodology (RSM)

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 09 Issue: 12 | Dec 2022 www.irjet.net p-ISSN: 2395-0072
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Multi objective Optimization of TIG welding AA6061 alloy using
response surface methodology (RSM)
Tadak Singh Kirade 1, Purushottam Sahu2
1Research Scholar BM College of Technology, Indore RGPV, BHOPAL
2Professor BM College of Technology, Indore RGPV, BHOPAL
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Abstract - This research paper discusses the experimental
and numerical results of AA6061 TIG welding. The purpose of
this research is to determine the best process parameters for
GTAW of Argon, which is used as an inert gasinthealuminium
alloy AA6061. The Taguchi method was used to optimize TIG
welding process characteristics such as gas flow rate, welding
current, and welding speed for connecting AA6061 plates. The
Taguchi technique is used to obtain the Optimization
parameters of Welding with tungsten inert gas on 6061
aluminium alloy. After examining the influence of various
components with ANOVA and regression analysis, theTaguchi
technique was used to find a desirable combination.
Key Words: Hybrid laser-TIG welding Response surface
methodology (RSM) Desirability approach, aluminium alloy
AA6061, welding current, gas flow rate
1. INTRODUCTION
The general principle TIG (tungsten inert gas) welding, also
known as GTA (gas tungsten arc) in the United States and
WIG (Wolfram inert gas) in Germany, is a welding process
used to produce high quality materials of varioustypesUsed
for welding, specifically, stainless steel, titanium and
aluminium.
1.2 Equipment
● AC / DC Power Source
● TIG Torch
● Work Return Welding Lead
● Shielding gas supply line, (normally from a cylinder)
● Foot Control Unit (common option)
Welding is the process of joining metalstogether, either with
or without filler, to form coal's essence. Welding is a method
of permanently joining materials.Shipbuilding,autos,andoil
and gas are just a few of the industries that employ it. Arc
welding is a process that involves creating an arc between
the electrode and the workpiece,whichwarmsandmeltsthe
metal. Electrodes can be consumable or non-consumable.
Flux is used to protect weld metal fromenvironmental gases.
The procedure can be carried either automatically or by
hand. In the shipbuilding business, arc welding, which was
pioneered in the nineteenth century, became commercially
vital during WWII. It's still utilised in the manufacturing of
steel pipelines and automobiles today. [2] Figure 1.1 Metal
arc welding with a consumable electrode shield. The most
popular, dependableandcost-effective weldingtechnologyis
shielded arc welding, often known as manual arc welding.
The consumable electrode utilised in this application is
compatible with flux-coatedweldedsteel.Anelectriccurrent
is utilised to strike an arc when the electrode is scratched
along the workpiece.
Figure 1.1 Classification of fusion welding processes.[46]
Figure 1.2 Shielded metal arc welding process [46]

Welding is a permanent joining process that uses heat,
pressure, and filler materials to connect two or more
materials, typically metals or thermoplastics.Tungsteninert
gas welding is an electric arc welding method that uses non-
consumable tungsten electrodes to create an arc between
the electrode tip and the work piece. To prevent
contamination of the weld with air, inert gases (argon,
helium, etc.) are used.
A mixture of any two of the gases described above is often
used. TIG welding is one of the most flexible welding
methods availabletoday,capableofconnectingtoalmost any
metal or metal alloy. This welding method is popular
because of its inherent benefits, such as high-quality and
better welds, less deformation, a smaller heat-affected zone,
and the absence of slag or spatter. TIG welding is widely
used in industrial industries such as automobiles, airplanes,
nuclear power plants, food processing plants, precision
manufacturing plants and maintenance and repair work.
[45]

2. RESPONSE SURFACE METHODOLOGY OF
EXPERIMENT
Fig. 5.1 Optimization results of impact strength by RSM
3. Confirmation test
The optimization results obtained have been validated by
performing confirmatory experiments. Table 6 represents
the results of confirmatory tests
that are conducted in optimal conditions. It is seen from the
table that the error in terms of percentage between the
estimated and experimental results is very small and is less
than 1%. This indicates that the optimized TIG welding
process parameters higher NTS and UTS of 316L stainless
steel can be obtained. Three fresh experiments are
conducted for confirmation of models Eqs. (3) And (4), with
achieved optimal values of cutting parameters. The average
of measured values for surface roughness and kerf taper
angle are tabulated in Table 6. The accuracy of the models
isanalyzed on the basis percentage error. These errors are
found to be 1.18 and 2.24% for surface roughness and kerf
taper angle, respectively. It is possibly due to some
vibrations during machining which affectsthemeasurement
techniques. Since the error is less than10%, it is evidently
proved that thereisa goodagreementbetween experimental
and predicted values [38].
Table 5.1Multi-objective optimization results
Fig. 5.2The effect of the process parameters on the Impact
strength :( a) welding current and gas flow rate (b) Welding
speed and welding current (c) gas flow rate r and welding
speed.
Fig. 5.3 Impact power contour plot (A) welding current and
gas flow rate) (B) and weldingspeedandweldingcurrent (C)
gas flow rate and welding speed
Optimal Control
Parameters
Level Optimal
Level
Experimental Predicted
(RSM)
Error
(%)
Welding
Current (A)
A A4 B2 C4 2.251 2.1737 5.3
Gas flow rate
(L/min)
B
Welding Speed
(mm/s)
C

Figure 6-8 shows the limits of impact strength (A) against
welding current (L / min), welding speed (mm / s) against
gas flow rate (L / min), and welding speed (mm / s) (A)
against the contour band welding current shown in (a). As
shown in fig. 6, the impact strength is greater when the
current is 190 A and the gas flow rate is 10 L/min.According
to Fig.7, maximum impact strength is obtained at high
welding speeds (54 mm/s) with a gas flow rate of 13 L/min.
4.CONCLUSION AND FUTURE APPLICATIONS
1. Response surface methodology (RSM) has been found to
be extremely useful in the current study's optimization
process. In this case, the predicted value from the models is
very close to the experimental value.
2. The most important welding parameter affectingultimate
tensile strength is gas flow rate, which is followed by
welding current and welding speeds.
3. The most important factor influencing percentage
elongation is welding current, with gas flow rate coming in
second, followed by welding speed.
5. Impact strength ANOVA result (J). It is discovered that the
most significant influence on impact strength is the Gas flow
rate (L/min) (P=0.393) (32.62%), followed by Welding
Speed (mm/s) (P=0.859) (6.90%) and the least significant
influence is the Welding Current (A) (P=0.900) (5.22%).
Welding current is an insignificantfactor forimpactstrength
in the current study.
6. According to the ANOVA analysis, gas flow rateisthemost
important factor influencing the impact strength of TIG
welded AA6061 joints, followed by welding speed.
REFERENCES:
[1] NabenduGhosh et.al. Parametric Optimization of Gas
Metal Arc Welding Process by using Taguchi method on
Ferritic Stainless Steel AISI409. Elsevier, Materials Today:
Proceedings 4 (2017) pg.2213–2221
[2] BhrudinHrinjica et.al.Welded Joint Tensile Strength
Testing Of New And Used Material. 16th International
Research/Expert Conference, TMT 2012, Dubai,UAE, 10-12
September 2012, pg 87-90
[3] Amit Pal. Mig Welding Parametric Optimization Using
Taguchi’s Orthogonal Array And Analysis Of Variance.
International Journal Of Research Review In Engineering
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[4] VivekSaxena et.al. Optimization Of MIG Welding
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