Improvement_of_Welding_Penetration_in_MI.pdf

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IJSRST1841194 | Received : 20 March 2018 | Accepted : 31 March 2018 | March-April-2018 (4) 5 : 1198-1203 2018 IJSRST | Volume 4 | Issue 5 | Print ISSN: 2395-6011 | Online ISSN: 2395-602X Themed Section: Science and Technology 1198 Improvement of Welding Penetration in MIG Welding Abrar Zaidi, Prof. K. R. Madavi PG Student, Government Engineering College, Aurangabad, Maharashtra, India Assistant Professor Government Engineering College, Aurangabad, Maharashtra, India ABSTRACT This investigation is to review the technique of using ACTIVATED FLUX for optimum penetration 4(5) : 1198-1203 1199 used on nearly all metals including carbon steel, stainless steel, alloy steel and aluminium. Arc travel speed is typically 30-38 cm/minute and weld metal deposition rate varies from 1.25 kg/hr when welding out of position to 5.5 kg/hr in flat position. Metal transfer across the arc, is short circuiting transfer, globular transfer, spray transfer, pulsed spray transfer. Figure 2.Figure 2. Schematic diagram of MIG welding Equipment Arrangement The made of weld metal transfer is determined by the following welding current, electrode size, electrode composition, electrode stick out, shielding gas. Joint type in MIG welding, the most commonly used joint type are the butt joint, corner joint, edge joint, lap joint and T-joint. Here, in MIG the arc is maintained between a consumable electrode and the work piece in an inert gas atmosphere. MIG welding gives much greater penetration and higher speeds. It is fast and more economical efficiency then TIG (Tungsten Inert Gas) Welding. C. GMAW / MIG welding applications C. GMAW / MIG welding applications MIG may be operated in semiautomatic, machine, or automatic modes. All commercially important applicable metals such as carbon steel, high-strength, low-alloy steel, and stainless steel, aluminium, copper, titanium, and nickel alloys can be welded in all positions with this process by choosing the appropriate shielding gas, electrode, and welding variables. D. Process parameter selectionD. Process parameter selection The welding parameters are selected by operator based on experience or from a handbook. However, this does not ensure that the selected welding process parameters can produce the optimal or near optimal weld pool geometry for that particular welding machine and environment. II. MATERIAL SELECTION Mild Steel - The chemical composition and properties of the material are as follows: - Physical Properties 1 Hardness in HRB - 90-91 210 HV 2 Tensile Strength - 649.66 N/mm2 3 Yield Strength - 540.88 N/mm2 4 Percentage Elongation - 11.79 5 The tests were conducted on metal strip of 50mm x 50mm square and 8 mm thickness sample. Application areas in the field of welding Application areas in the field of welding The tank and vessel industry consisting of boilers, pressure vessels, other storage tankers. This material is easily available and easily wieldable makes it suitable for the use of many more applications related to welding. Chemical Composition Table- TABLE 1 Sr. No. Name of Constituent Percentage % 1 Carbon 0.20 2 Nickel 0.01 3 Phosphorous 0.035 4 Manganese 0.65 5 Molybdenum 0.002 6 Silicon 0.23 7 Chromium 0.02 8 Sulphur 0.026 Material Selection Material Selection 1. ASTM (A36) IS2062 Carbon steel 2. Also known as Plain carbon steel 3. Material contain carbon 0.05 to 025% 4. It is malleable in nature 5. It is also ductile in nature International Journal of Scientific Research in Science and Technology () Abrar Zaidi et al. Int J S Res Sci. Tech. 2018 Mar-Apr;4(5) : 1198-1203 1200 6. It is having good weld ability 7. It is used in high pressure vessel and boilers 8. It is also used for manufacturing various machine parts 9. It has low tensile strength 10. It is having high fracture toughness 11. It is having melting point 1300C to 1400C 12. Density of material is7.85g/cm2 13. Youngs modulus 200 GPA 14. Elements, such as niobium, vanadium and titanium added singly or in combination to obtain higher strength to weight ratio combined with better toughness, formability and weld ability as compared to unalloyed steel of similar strength level. WELDING PARAMETERSWELDING PARAMETERS VariableVariable Current- recommended 150A ( results taken at 100A, 125A, 150A) Arc voltage- recommended 25V (results observed at 20V, 25V, 30V) Gas flow rate- 14L/min(results observed at 12L/min, 14L/min, 16L/min) Surface active elements/flux (Fe2O3 4(5) : 1198-1203 1201 done. Ensure that the flux applied is constant over the surface of the weld. FigFigure ure 4 4. . The application of flux Step 1: The base material is first cut as per required sizes of 50mm X 50mm X 8mm through a bench cutter. Step 2: Using grinder on bench, the burr is removed from the workpiece to obtain smooth contact surface. FigFigure ure 5 5. . Application of flux between two plates to be welded Step 3: For obtaining highly smooth contact surface, the surface are then buffed through buffing wheel. Step 4: The next step is to apply
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