Optimization of stainless-steel cladding onto mild steel using the Gmaw process

Abstract

Pipe welding is a significant yet demanding technique within welding technology. The Gas Metal Arc Welding (GMAW) cladding method is crucial in metal fabrication, particularly in manufacturing long-lasting materials suitable for extreme acidic and alkaline environments. The advantage of GMAW process is that it eliminates the need for post-weld finishing due to the absence of slag, coupled with a high welding speed that boosts productivity. However, a comprehensive understanding of the equipment is essential, from procurement to production, to effectively monitor and control the welding process and prevent defects. Optimization is critical, given the high demands for accuracy and efficiency stemming from the complexities of welding. The main goal was to identify the best GMAW conditions for applying a corrosion-resistant stainless-steel coating on mild steel substrates. Specific aims included establishing GMAW parameters, identifying factors affecting dilution, and optimizing variables for superior clad welding quality. The study included an experimental approach that followed a thorough literature review to identify suitable materials. The experimental framework utilized multiple trial runs based on the Taguchi design of experiments (DOE). The main parameters targeted for optimization were welding current, wire feed rate, and arc voltage, which were crucial for improving corrosion resistance, bead configuration, and weld dilution. The methodology was systematic, covering factor identification, response characterization, limit determination for process variables, design matrix creation, material selection, experimental execution, data collection, statistical analysis, and result verification. Results indicated significant metrics: bead width at 99.99%, penetration at 95.72%, and reinforcement at 96.4%, with a minimum dilution of 6.67%, all optimized at a 95% confidence level.