Assessment of arc stability characteristics in gas metal arc welding and related weld quality

Abstract

Gas Metal Arc Welding (GMAW) is a widely employed welding process, and the stability of the welding arc serves as a crucial indicator influencing the overall efficiency of the welding procedure. Arc stability is intricately linked to various quality metrics such as spattering, weld formation, and penetration. While numerous studies have explored arc stability, few have delved into its direct correlation with weld quality. This research addressed this gap by examining how welding parameters, particularly protective gas combinations specifically carbon dioxide and argon affect arc stability. The study involved measuring arc voltage, arc length, and determining arc behaviour under different protective gas combinations. The obtained values were meticulously compared using plotted graphs, offering insights into the behaviour of arc stability in Gas Metal Arc Welding of mild steel. To substantiate the findings, samples generated from experiments utilizing distinct protective gas combinations were subjected to visual inspection, mechanical property testing, and metallographic examination. This comprehensive analysis aimed at elucidating the effects of varied gas combinations on weld quality. The visual, mechanical, and metallographic results were correlated to draw meaningful conclusions regarding arc stability. The 100% argon shielding gas yielded the most stable welding process at a speed of 40 mm/minute, amperage of 150A and voltage of 25v. These parameters hold great significance for future applications in welding machine design and manufacturing. This research contributes to the existing body of knowledge by bridging the gap between arc stability and weld quality, offering practical insights that can inform welding practices and equipment design. The methodologies employed and conclusions drawn from this study serve as a foundation for future advancements in the optimization of weld quality through a comprehensive understanding of arc stability in GMAW processes.