Process parameter optimization of gas metal arc welding on IS:2062 mild steel using response surface methodology

Quality of weld mainly depends on mechanical properties of the weld metal and heat affected zone (HAZ), which isin direct relation to the type of welding and its process parameters.Bead geometry variables, heat affected zone, bead width, bead height, penetration and area of penetration are greatly influenced by welding process parameter i.e. welding speed, welding current, shielding gas flow rate, voltage, arc travel speed, contact tip - work distance, type of shielding gas etc. and also it plays an important role in determining the mechanical properties of the weld such as tensile strength, hardness etc.In this paper, effect of the various process parameters has been studied on welding of IS:2062 mild steel plate using gas metal arc welding process with a copper coated mild steel wire of 0.8 mm diameter. A set of experimentshas been performed to collect the data using Box Behnken Design technique of Response Surface Methodology. Based on the recorded data, the mathematical models have been developed. Further an attempt has been made to minimize the bead width and bead height and maximize the depth of penetration using response surface methodology.