Analysis of dilution response surfaces and bead morphology in MIG-welding process

Abstract

The complexity of the current welding processes, as well as their sensitivity and precision, make it necessary to use statistical methods and optimization, accompanied by the search for experimental error and the adjustment of the model obtained, aiming at reducing time and cost. Although there are numerous treatments that have emerged over time, the Response Surface Methodology (MSR) has become one of the most appropriate ways to manage research related to this scope, by combining design and analysis of experiments, modeling and optimization. In addition, the search for processes that adjust to the needs imposed in the current scenario for coating, leads to the research of new welding processes, which combine low dilution, with maximized reinforcement width and height values, with only one layer. This difficulty causes welding processes to be conducted in conjunction with these tools, making the process more efficient. In this sense, with the objective of joining the two fronts exposed, the present work, through the use of Box-Behnken (BBD), sought to analyze the MSR of the dilution, width and height of reinforcement, with the use of MIG-PV welding, with filler metal AWS A5.9 ER385 (analogous to AISI 904L) in position (1G) on free surface (bead-on-plate) on ASTM A36 carbon steel substrate, with a thickness of 6.35 mm, in addition to optimizing the process via desirability with reinforcement height. The result showed that the input values were adjusted, considering the R2 values of 88%, as well as the morphology of the surfaces. In addition, it showed maximum desirability in optimization, with an experimental error of 8.8%, with average height values of 5.2 mm, having great application in the current industry, with only one layer.

DOI:https://doi.org/10.56238/sevened2024.010-051