Modeling of Weld Bead Geometry and Shape Relationships in Submerged Arc Welding using Developed Fluxes

To automate a welding process, which is the present trend in fabrication industry, it is essential that mathematical models have to be developed to relate the process variables to the weld bead parameters. Submerged arc welding (SAW) is characterized by its high reliability, deep penetration, smooth finish and high productivity especially for welding of pipes and boiler joints. In the present work mathematical models have been developed for SAW using developed fluxes. Response surface methodology has been used to predict critical dimensions of the weld bead geometry and shape relationships. The models developed have been checked for their adequacy and significance by using the F-test and the t-test, respectively. Main and interaction effects of the process variables on bead geometry and shape factors are presented in graphical form and using which not only the prediction of important weld bead dimensions and shape relationships but also controlling the weld bead quality by selecting appropriate process parameter values are possible.