Prediction and optimization of weld bead volume for the submerged arc process - Part 2

As a part of a study and analysis on the effects of process parameters on weld bead volume in submerged are welding (SAW) of pipes, mathematical models were developed to relate the process parameters and the weld bead quality parameters. Further, the optimization of weld bead volume was carried out using the optimization module available in the MATLAB version 4.2b software package. The mathematical models thus developed for optimization are also helpful in predicting the weld bead quality parameters and in setting process parameters at optimum values to achieve the desirable weld bead quality at a relatively low cost with a high degree of repeatability and increased production rate. Total volume of the weld bead, an important bead parameter, was optimized (minimized), keeping the dimensions of the other important bead parameters as constraints, to obtain sound and superior quality welded pipes. Sensitivity analysis was also carried out to predict the direct and few interaction effects of important bead parameters on the total volume of the weld bead, and the results are presented in graphical form. The results of the sensitivity analy sis are very useful in understanding the interdependence of various weld bead quality parameters in controlling the volume of the weld bead, to improve weld quality, to increase productivity with the available welding facilities and to minimize the total welding cost.