Optimization and control of bending distortion of submerged arc welding I-beams

In this study, the bending distortion of I-beams fabricated from steel sheets using submerged arc welding (SAW) is investigated. Bending distortion occurs due to non-uniform distribution of heat generated during welding. It is believed that distortion can be minimized by suitable selection of the input parameters of the welding process. In order to optimize the welding parameters to minimize the bending distortion, a direct experiment is conducted at a manufacturing plant fabricating I-beams. The study employs methods of design of experiments (DoE) and analysis of variance (ANOVA) to detect the significant parameters affecting the response “the bending distortion”. Welding arc voltage, wire feed speed, and welding travel speed are examined by performing three-level full factorial design in three blocks. Based on the specifications of the I-beam (web and flange dimensions), the objective is to properly select the SAW machine's parameters that could minimize the bending distortion.