PSM 1 (Edited To PSM 2) - Repair

SUBMERGE ARC WELDING EVOLUTION OF CARBON
STEEL PLATE
ZAINAL ABIDDIN SHAH BIN MATTAR
A thesis submitted in fulfillment of the

requirements for the award of the Bachelor’s Degree of Mechanical Engineering
FACULTY OF MECHANICAL ENGINEERING

UNIVERSITI TEKNOLOGI MALAYSIA
September 2009
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I declare that this thesis entitled “Submerge Arc Welding Evolution of Carbon Steel
Plate” is the result of my own research except as cited in the references. The thesis
has not been accepted for any degree and is not concurrently submitted in
candidature of any other degree.”
Signature : ..........................................................................
Name : ZAINAL ABIDDIN SHAH BIN MATTAR
Date : ............................................. ............................

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To my beloved family and friends

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ACKNOWLEDGEMENT
Firstly, thanks to Allah for giving a good health and mind which enable the
author to face and overcome various problems and complete this research.
The author would like to express deepest appreciation to supervisor, PM

Zainal Abidin Bin Ahmad for supervising the author all the way and offered for
many suggestions and helps in conducting the research to fulfill this project.
Thousand thanks also go to the author’s family for their love and support.
Not forgetting, to all friends who have been very helpful and give the author
encouragement to finish the research especially to my colleagues in Fabrication and
Joining Department University Kuala Lumpur Malaysia France Institute
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ABSTRACT
Selection of process parameters has great influence on the quality of a

welded connection. Mathematical modeling can be utilized in the optimization and
control procedure of parameters. Changeable process parameters such as welding
current, welding voltage and welding speed are used as design variables. Experiment
of this study base on Taguchi method which has two level factorial designs of four
process parameters. In order to investigate the effects of input (process) parameters
on output parameters, software MINITAB which containing Taguchi analysis and
statistical analysis of variance (ANOVA) was carried out. Based on the MINITAB
the contribution of each process parameter and their interaction in influencing the
quality characteristic is evaluated. MINITAB also provides an indication of which
process parameters are statistically significant. The optimum process parameter
combination is predicted and verified. Effects of all four design parameters on the
bead width and bead height show that even small changes in these parameters play
an important role in the quality of welding operation
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ABSTRAK
Pemilihan proses kimpalan memberi pengaruh yang besar terhadap kualiti

sambungan kimpalan. .Metametik model boleh di gunakan dalam pemilihan untuk
menentukan ketepatan sebenar dan untuk mengawal parameter mesin kimpalan.
Perubahan dalam parameter seperti current kimpalan, voltage kimpalan, kelajuan
kimpalan di pilih sebagai perbagaian faktor kimpalan. Ujikaji di lakukan mengikut
method Taguchi di mana dalam ujikaji ini, empat faktor kimpalan dan dua level bagi
setiap faktor kimpalan telah di gunakan. Untuk menilai ketepatan ujikaji, sorfware
MINITAB yang mana di dalamnya mengandungi analisa Taguchi dan analisa
statistik variance (ANOVA) telah di pilih untuk membuat analisis. Berdasarkan
analisis yang dibuat contribute bagi setiap faktor kimpalan berkait rapat dengan
kualiti kimpalan. MINITAB juga boleh menunjukan dan mengenal pasti faktor
kimpalan yang benar benar mempengaruhi kualiti dan ketepatan.Ia juga boleh
menunjukan dan mengenalpasti hubung kait di antara faktor faktor kimpalan
Walaupun terdapat sedikit perubahan dalam factor kimpalan yang digunakan tetapi
ia memberi kesan yang besar terhadap kualiti proses kimpalan.
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TABLE OF CONTENTS
CHAPTER TITLE PAGE
TITLE PAGE i
DECLARATION OF ORIGINALITY ii
DEDICATION iii
ACKNOWLEDGEMENTS iv
ABSTRACT v
ABSTRAK vi
TABLE OF CONTENTS vii
LIST OF TABLES xi
LIST OF FIGURES xiii
LIST OF SYMBOLS xiv
LIST OF APPENDICES xvi
1 INRODUCTION
1.1 Introduction 1
1.2 Flow Chart of the project planning 3
1.3 Objective 4
1.4 Methodology
1.4.1 Taguchi Method 4
1.4.2 Minitab Software 5
1.4.3 Analysis of variance ANOVA 6
2 LITERATURE REVIEW
2.1 Submerge Arc welding 7
2.2 Submerge Process 8
2.3 Application 10
2.4 Flux 11
2.5 Feature 12
2.5.1 Electrode 12
2.5.2 Submerge Arc Welding Process Variable 14
2.5.2.1 Amperage/Wire Feed Speed (WPS) 14
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2.5.2.2 Arc Voltage 15

2.5.2.3 Travel Speed 16
2.5.2.5 Electrode Extension 17
2.5.2.6 Polarity and Current Type 18
2.5.2.7 Other Factor 19
2.6 Advantages 20
2.7 Limitations 20
2.8 SAW Benefit 20
3 METHODOLOGY
3.1 Methodology 21
3.2 Experiment Procedure 25
3.3 Mechanical Properties 29
3.2.1 Tensile Strength 29
3.2.1.1 Weld Metal Tensile Strength Test 30
3.2.1.2 Test Procedure 31
3.2.2 Hardness Test 31
3.2.1.1 Procedure of Hardness Test 32
3.2.1.2 Procedure for Measuring Hardness 32
3.2.3 Deposition 34
3.2.4 Micro Structures 34
3.2.4.1 Concept and Purpose 36
3.2.4.2. Preparation of Test Specimen 37
3.2.4.3 Etching Reagents 38
4 RESULTS AND ANALYSIS

4.1 Result for tensile Test 39
4.2 Result for Hardness Test 41
4.3 Result for Deposition 42
4.4 Experiment Data Result 43
4.4.1 Example to find Tensile 44
4.4.2 Example to Find Hardness 44
4.4.3 Example to find Deposition 44
4.5 Micro Structure Result 45
4.6 Analyze using Taguchi Design 47
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4.7 Analyze Result and Graph 53

4.8 Optimization of Parameter 54
5 DISCUSSION 55
6 56
CONCLUSION
REFERENCE 57
LIST OF TABLES
TABLE NO. TITLE PAGE

2.1 Wire ,current and voltage 13
3.1 Chemical composition of the base metal and filler 22
material
3.2 Working rate of the process parameter 22
3.3 Orthogonal array for L8 (27) Taguchi design 23
4.1 Result for Tensile test 39
4.2 Result for Hardness test 42
4.3 Result for Deposition test 42
4.4 Orthogonal result for L8 (27) Taguchi method 43
4.5 Analysis Data for Tensile 53
4.6 Analysis Data for Hardness 53
4.7 Analysis Data for Deposition 53
4.8 Summary of the result 54
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LIST OF FIGURES
FIGURE NO. TITLE PAGE

2.1 Submerge Arc Welding Processes 8
2.2 Equipment for Submerge Arc welding 9
2.3 Submerge Configuration 10
2.4 Wire and Flux Identification 12
2.5 Wire Size 13
2.6 Amperage Varied Weld 14
2.7 Voltage Varied Weld 15
2.8 Travel Speed 16
2.9 Polarity varied weld 19
3.1 Side View of specimen 23
3.2 Schematic of welding with respective rolling 24
direction
3.3 Dimension of Tensile Specimen 24
3.4 Plate cutting 25
3.5 Square and bevel process 25
3.6 Backing plate process 26
3.7 Brushing process 26
3.8 Saw machine 27
3.9 Saw display machine 27
3.10 Wire stick out measured 27
3.11 Welding progress 27
3.12 Sample for sheet 5 27
3.13 Sample for sheet 8 27
3.14 Band saw machine 28
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3.15 Specimen sample 28

3.16 Welding bead grinding 28
3.17 Numbering process 28
3.18 Throat cutting 28
3.19 Radius cutting 28
3.20 Tensile machine – Model Hung Ta – 500T 29
3.21 Tensile progress 29
3.22 Specimen before testing 30
3.23 Specimen after welding 30
3.24 Hardness machine –Yata HMT - IT 31
3.25 Specimen testing 31
3.26 Schematic sketch of hardness welding 33
area
3.27 Polishing machine Model MetaServ 2000 35
3.28 Polishing process 35
3.29 Microscope Olympus Model BX4M 35
4.1 Tensile report for specimen no. 5 40
4.2 Load versus welding area graph 42
4.3 Microstructure of base metal 45
4.4 Microstructure of specimen no.1 45
4.12 Main Effect Plot for Tensile 47
4.13 Main Effect Plot for Hardness 47
4.14 Main Effect Plot for Deposition 48
4.15 Interaction Graph between A x B for 48
Tensile
4.16 Interaction Graph between A x C for 49
Tensile
4.17 Interaction Graph between B x C for 49
Tensile
Hardness
Hardness
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Hardness
Deposition
Deposition
Deposition
LIST OF APPENDICES
APPENDIX TITLE
A Test Report for Tensile Specimen 59
B Welding Procedure Specification (WPS) 68
C Prequalifed PJP Groove Weld 70
D Prequalifed Base Metal –Filler Combination for 72
Matching Strength
E Prequalifed Minimum Preheat and Interpass 76
Temperature
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1
Chapter 1
Introduction
1.1 Introduction
Carbon SteelA36 steel is a standard steel alloy which is a common

structural steel used. As with most steels, A36 has a density of
0.28 lb/in³ (7.8 g/cm³). A36 steel in plates, bars, and shapes with a
thickness of less than 8 in (200 mm) has a minimum yield strength
of 36,000 psi (250 MPa) and ultimate tensile strength of 58,000–
80,000 psi (400–550 MPa).Plates thicker than 8 in have a
32,000 psi (220 MPa) yield strength and the same ultimate tensile
strength. A36 is a standard carbon steel without advanced
alloying.
Carbon steel plate is extensively used in heavy fabrication

industries like ship and bridge structure and pressure vessel
construction. For this study Carbon steel ASTM 36 was decide as a
specimen to be weld using SAW welding. Submerged Arc Welding
(SAW) process performs with high productivity coupled with
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satisfactory penetration, good deposition rate, and smooth spatter

free weld and has easy weld control. SAW is preferred for high
thickness metal sheets / plates maximum thickness 25 mm. and
where extremely high deposition rate is required .It has wide
applications in the areas of fabrication of pressure vessels,
locomotives, etc. The strength of SAW joints are however not
always satisfactory and depends on proper selection of various
welding parameters.
The parameters SAW are welding current, voltage, speed of
welding electrode, electrode diameter, number of passes, type of
flux used, width & depth of layer of flux, etc. These parameters
influence the mode of metal transfer, the nature of protection
offered by flux covering and the strength of the welded joint.
The Submerged Arc Welding (SAW) process finds wide industrial
application due to its easy applicability, high current density and
ability to deposit a large amount of weld metal using more than
one wire at the same time. It is highly emphasized in
manufacturing especially because of its ability to restore worn
parts. SAW is characterized by a large number of process
parameters influencing the performance outputs such as
deposition rate, dilution and hardness, which subsequently affect
weld quality. An exhaustive literature survey indicates that five
control factors, arc current, arc voltage, welding speed, electrode
stick-out and preheat temperature, predominantly influence weld
quality. In relation to this, an attempt has been made in this study
to analyze the effect of process parameters on outputs of welding
using the Taguchi method.
The quality characteristics, such as tensile strength, hardness,
impact toughness, and dilution of the base metal into the weld
were evaluated for all the trials and then statistical analysis of
variance (ANOVA) was carried out. Based on the ANOVA, the
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contribution of each process parameter and their interaction in

influencing the quality characteristic is evaluated. The ANOVA also
provides an indication of which process parameters are statistically
significant. The optimum process parameter combination is
predicted and verified. The relationship between control factors
and performance outputs is established by means of nonlinear
regression analysis, resulting in a valid mathematical model.
Finally, Genetic Algorithm (GA), a popular evolutionary approach, is
employed to optimize the welding process with multiple objectives.
1.2 Flow Chart of Project Planning

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1.3 Objective
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To find out the optimal welding process parameter of submerge arc

welding for four mechanical performance characteristics such as
tensile, hardness, deposition rate and dilution on carbon steel
ASTM 36. Factors such as arc current, arc voltage and welding
speed, wire stick-out and their interactions play a significant role in
the SAW process.
1.4 Methodology
1.4.1 Taguchi method
Taguchi method is a new method of conducting the design of

experiments which are based on well defined guidelines. This
method uses a special set of arrays called orthogonal arrays. These
standard arrays stipulate the way of conducting the minimal
number of experiments which could give the full information of all
the factors that affect the performance parameter. The crux of the
orthogonal arrays method lies in choosing the level combinations
of the input design variables for each experiment.
Taguchi’s philosophy is an efficient tool for the design of high

quality manufacturing system. Dr. Genichi Taguchi,[7] a Japanese
quality management consultant, has developed a method based on
orthogonal array experiments, which provides much-reduced
variance for the experiment with optimum setting of process
control parameters. Thus the integration of design of experiments
(DOE) with parametric optimization of process to obtain desired
results is achieved in the Taguchi method. Orthogonal array (OA)
provides a set of well-balanced (minimum experimental runs)
experiments and Taguchi’s signal-to noise ratios (S/N), which is
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logarithmic functions of desired output serve as objective functions

for optimization. This technique helps in data analysis and
prediction of optimum results. In order to evaluate optimal
parameter settings, Taguchi method uses a statistical measure of
performance called signal-to-noise ratio. The S/N ratio takes both
the mean and the variability into account. The S/ N ratio is the ratio
of the mean (signal) to the standard deviation (noise). The ratio
depends on the quality characteristics of the product/process to be
optimized, Maghsoodloo et al. [7]. The standard S/N ratios
generally used are as follows: Nominal is best (NB), lower the
better (LB) and higher the better (HB). The optimal setting is the
parameter combination, which has the highest S/N ratio.
Where De, Di and Hr represent the response for deposition rate,

dilution and hardness
respectively and ‘n’ denotes the number of experiments.
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1.4.2 Minitab Software
Analysis of experiment data was carried out using MINITAB

software. Minitab is a statistical program with a spreadsheet-like
data worksheet. It is capable of manipulating and transforming the
data and can produce graphical and numerical summaries. Minitab
also can perform a wide variety of statistical computations. It can
be used for learning about statistics as well as statistical research.
Statistical analysis computer applications have the advantage of
being accurate, reliable, and generally faster than computing
statistics and drawing graphs by hand. .
1.4.3 Analysis of variance (ANOVA)
An ANOVA is an analysis of the variation present in an experiment.

It is a test of the hypothesis that the variation in an experiment is
no greater than that due to normal variation of individuals'
characteristics and error in their measurement.
The method is very useful to reveal the level of significance of
influence of factor(s) or interaction of factors on a particular
response. It separates the total variability of the response (sum of
squared deviations about the grand mean) into contributions
rendered by each of the parameter/ factor and the error. Thus
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Chapter 2
Literature Review
2.1 Submerged Arc Welding (SAW)
The Submerged Arc Welding (SAW) process involves formation of

an arc between a continuously fed bare wire electrode and the
work piece. The process uses a flux to generate protective gases
and slag, and to add alloying elements to the weld pool. A
shielding gas is not required. Prior to welding, a thin layer of flux
powder is placed on the work piece surface. The arc moves along
the weld line and as it does so, excess flux is recycled via a
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hopper. Remaining fused slag layers can be easily removed after

welding. As the arc is completely covered by the flux layer, heat
loss is extremely low. This produces a thermal efficiency as high as
60% (compared with 25% for manual metal arc). There is no visible
arc light, welding is spatter-free and there is no need for fume
extraction.
SAW is usually operated as a fully mechanized or automatic

process, but it can be semi-automatic. Welding parameters, which
include current, arc voltage and travel speed, all affect bead
shape, depth of penetration and chemical composition of the
deposited weld metal. Because the operator cannot see the weld
pool, reliance must be placed on parameter settings.
There is virtually no restriction on the material thickness, provided

the work piece is suitably prepared. Most commonly welded
materials are carbon-manganese steels, low alloy steels and
stainless steels, although the process is capable of welding some
non-ferrous materials with judicious choice of electrode filler wire
and flux combinations. In cutting systems and wear reduction
applications, the weld is typically made in a machined pocket, and
then ground to a sharp square edge.
2.2 Submerge Processes
In the Submerged Arc Welding (SAW) process, schematically shown

in Figure 2.1, flux is laid in granular form on the unwedded seam
ahead of the bare metal electrode to provide shielding. The
electrode is fed from a coil to allow a continuous and uninterrupted
welding operation. The flux is effective in preventing the
atmosphere from contaminating the molten weld metal.
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Figure 2.1: SAW Process
The arc is struck beneath the flux between the bare electrode and
the work piece, which melts a small amount of flux. The heat
generated by the arc melts the end of the electrode, the flux, and
part of the base metal at the weld seam. The arc transfers the
molten metal from the tip of the melting electrode to the work
piece where it becomes deposited metal. As the molten flux
combines with the molten metal, chemical reactions occur that
remove some impurities and/or adjust the composition of the weld
metal.
While still molten, the flux which is lighter than the weld metal
rises to the surface of the weld pool and protects it from oxidation
and contamination. On further cooling, the weld metal solidifies at
the trailing edge of the moving weld pool, and the weld bead
usually has a smooth surface due to the presence of the molten
glass-like slag above it. The slag freezes next and continues to
protect the weld as it cools. Solidified slag is readily removable,
sometimes popping off the bead spontaneously. Excess, unmelted
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flux can be recovered and reused after proper processing. The

equipment set-up for single electrode SAW is shown in Figure 2.2
Figure 2.2: Equipment for SAW
One of the great advantages of the SAW process is its adaptation

to the use of multiple
Electrodes fed into the same weld pool thus considerably
increasing deposition rates. Some of the configurations for multiple
electrodes SAW are shown in Figure 2.3.
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Figure 2.3: SAW Configurations
In addition, multiple welding heads can be included into the

welding procedure so that
Subsequent passes can be deposited before the slag from previous
passes solidify, allowing a weld to be completed on thicker sections
in a single run. Because of the additional heat sources associated
with multiple electrodes welding, the weld zone can cool slowly
leading to excessive HAZ grain growth and microstructures with
poor mechanical properties. In these cases, procedures or
processes must be adopted that improve deposition rates or
reduce the heat transferred to the material, to allow for increased
cooling rates and finer weld metal and heat affected zone grain
sizes. To do this effectively, the processes adopted must not reduce
productivity rates or increase the cost of fabrication.
2.3 Application
SAW is ideally suited for longitudinal and circumferential butt and fillet welds.
However, because of high fluidity of the weld pool, molten slag and loose flux layer,
welding is generally carried out on butt joints in the flat position and fillet joints in
both the flat and horizontal-vertical positions. For circumferential joints, the work
piece is rotated under a fixed welding head with welding taking place in the flat
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position. Depending on material thickness, either single-pass, two-pass or

multiphase weld procedures can be carried out. There is virtually no restriction on
the material thickness, provided a suitable joint preparation is adopted. Most
commonly welded materials are carbon-manganese steels, low alloy steels and
stainless steels, although the process is capable of welding some non-ferrous
materials with judicious choice of electrode filler wire and flux combinations.
2.4 Flux
Fluxes used in SAW are granular fusible minerals containing oxides of manganese,
silicon, titanium, aluminum, calcium, zirconium, magnesium and other compounds
such as calcium fluoride. The flux is specially formulated to be compatible with a
given electrode wire type so that the combination of flux and wire yields desired
mechanical properties. All fluxes react with the weld pool to produce the weld metal
chemical composition and mechanical properties. It is common practice to refer to
fluxes as 'active' if they add manganese and silicon to the weld, the amount of
manganese and silicon added is influenced by the arc voltage and the welding
current level. The main types of flux for SAW are:
 Bonded fluxes - produced by drying the ingredients, then bonding them with
a low melting point compound such as a sodium silicate. Most bonded fluxes
contain metallic deoxidizers which help to prevent weld porosity. These
fluxes are effective over rust and mill scale.
 Fused fluxes - produced by mixing the ingredients, then melting them in an

electric furnace to form a chemically homogeneous product, cooled and
ground to the required particle size. Smooth stable arcs, with welding
currents up to 2000A and consistent weld metal properties, are the main
attraction of these fluxes.
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2.5 Features
2.5.1 Electrode
The electrode diameter choice can affect weld bead shape and
penetration depth for a fixed current setting. Small electrodes are
used in semi-automatic applications because of the flexibility and
ease of handling. They are also used with dual wire and tandem
wire systems.
Large wire diameter is generally used for poor fit-up because of
their ability to bridge large root openings. The electrode diameter
will affect deposition rates. At a given current setting, a small wire
will give a higher current density and thus a higher deposition rate
than a larger diameter wire. However, a larger wire can carry more
current so larger wire gives deposition rate at higher current. For a
given diameter size, a high current gives a high current density
with deep penetration of the base plate. Low current on the same
size wire gives a less penetration arc. Wire size also affects arc
starting. Small diameter wire arc starts are more consistent.
Automatic submerge arc will begin most often with 1/16” diameter
wire with a common maximum of 3/16”or ¼: diameter wire.
Occasional situation will show a need for 5/16, 1/4 or 3/8” diameter
wire. However multiple head and narrow groove applications seem
to have decreased the need for the excessively large single wires.
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Figure 2.4: Wire and Flux Identification
Figure 2.5: Wire Size
Listed are some current and voltage ranges for commonly

accepted wire diameter. These are approximate values –fluxes,
wire type, AC vs. DC, polarity, and electrode extension, type of
power source, joint design and material thicknesses may cause
these to vary quite extensively
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Table 2.1: Wire & Current and Voltage
2.5.2 SAW process variables
2.5.2.1 Amperage/wire Feed Speed (WPS)
Figure 2.6: Amperage varied weld

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Ampere and WPS are directly related to each other in that as

wire feed speed is increased, amperage will also increase. If
wire feed speed is reduced, amperage will also reduced. This
assumes all other variables have remained constant, and
that a CP power source and constant speed feeder are being
used.
Amperage /WFS controls wire melt off rate, depth of
penetration and the amount of base metal dilution. Too high
amperage and the amount/wire feed speed at a given travel
speed will result in too great a depth of fusion or penetration.
The weld may penetrate so far that melt-thru of the backing
may occur. Too high an amperage/wire speed for a given
condition can cause excessive weld reinforcement, increased
weld shrinkage, added stress and a greater chance of
distortion. Too low amperage/WFS results in inadequate
penetration, lack of proper fusion, and insufficient joint fill
(low deposition)
2.5.2.2 Arc Voltage

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Figure 2.7: Voltage Varied Welds
The primary function of voltage is to control the shape of the

bead cross section and its outward appearance. Any variation
in arc voltage creates a change in arc length. An arc voltage
increase brings an arc length increase, an arc voltage
decrease brings an arc length decrease:
Increase the arc voltage with amperage and travel speed
held constant will:
i. Produce flatter and wider beads
ii. Increase flux consumption
iii. Improve slag removal on straight butt and fillet welds
iv. Reduce porosity caused by rust and mill scale
v. Bridge gaps when poor fit up occurs
vi. Increase pickup of alloying elements from alloy fluxes
into the weld deposit. This can be used to advantages
when trying to raise the alloy content of the weld.
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Excessively high arc voltage will:

i. Produce a hat shaped wide bead subject to cracking
(single pass welding)
ii. Hinder slag removal
iii. Produce a concave shaped weld bead which will be
subject to cracking (multiple pass in a grove).
iv. Provide increased alloy pickup in multiple pass weld,
thereby increasing chances of cracking
v. Increase edge undercutting on fillet welds
2.5.2.3 Travel Speed
Figure 2.8: Travel Speed
Travel speed is one of the most important variable affecting

penetration and bead size. High speeds decrease penetration and
increase tendencies for undercut, arc blow, porosity and non-
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uniform bead shape. Proper speeds give gases time to escape from
the molten meld before it solidifies, which reduces porosity. Very
slow speeds will produce bead shapes that are subject to cracking,
excessive open arc exposure for the welding operator and a large,
uncontrollable molten pool that results in a rough bead and
possible slag inclusions
For a single pass welds, the current and travel speed should be as
high as possible and still obtain proper weld bead size and proper
penetration without burning through. In multiple pass welding, the
travel speed can be varied to obtain the desired fill for the joint.
2.5.2.4 Electrode Extension
Electrode extension is the distance from the contact tip to the base
metal. As this distance increases, amperage will drop off which
results in less penetration, narrower bead and more build up. If
wire feed speed is increased to return amperage to its previous
level, this will increase deposition rate. The increased wire feed
speed and amperage still will not achieve as much penetration as
when the short electrode extension is used. However, this can be
used to advantages when deep penetration is not required.
If electrode extension is reduced, amperage will increase. The

penetration and bead width increase also. As experience is gained,
the ability to optimize the wire electrode extension to achieve the
best deposition rate and penetration characteristics for each
particular weldment is realized.
As rule of thumb for setting wire extension is to go eight times the
wire diameter. (Example: If 1/8” wire is used, the extension would
be eight times 1/8” or approximately 1”)
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2.5.2.5 Polarity and Current Type (AC or DC)
Direct current is most commonly used but base metal type, joint
design and thickness are factors when choosing polarity. DC
usually provides more control over the bead shape, penetration,
deposition and welding speed. DC makes arc starting easier than
conventional Ac power supplies, although Square Wave AC Sub Arc
does provide most of the same features with very reliable arc start.
Both conventional AC and Square Wave AC output power source
greatly reduce the possibility of arc blow problems.
Direct Current Reverse Polarity (DCRP- electrode positive) provides

the best control of bead shape and maximum penetration. The
deep penetration allows the use of small welding grooves or no
groove at all in thin material, minimizing the amount of filler metal
per foot of joint and permitting fast welding speeds. These high
speeds lessen the total heat input and tend to reduce the problem
of heat distortion. Reverse polarity also has a tendency to produce
less weld porosity as opposed to straight polarity
Straight Polarity (electrode negative – DCSP) is used to reduce
penetration. The deposition rate is improved because faster wire
feed speeds are required to achieve the same current as DCRP. DC
Straight Polarity is often used:
i. On clean plate, free from rust and mill scale for fillet welds
ii. On occasions where deep penetration is not required
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iii. On hard surface applications where higher melt-off rates are

desired and less base metal dilution
iv. Where reduced admixture (dilution) of filler metal with base
metal is required. This is true for hard-to –weld steel. Straight
polarity’s shallow penetration is needed to lessen cracking or
porosity
v. Where greater build up is needed, but less penetration, to
stop cracking in primary passes of deep groove weldments
A switch from reverse to straight polarity should be accompanied

by an approximate 3-4 volt increase. Holding the current at same
level as the reverse polarity setting is recommended to maintain
the same bead shape.
The Sub Arc process operates with a very stable arc. This maintains
good weld quality and keeps possible weld repair to a minimum.
This reliability can substantially boost weld productivity.
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Figure 2.9: Polarity varied weld
2.5.2.6 Other factors

 Flux depth/width;
 Flux and electrode classification and type;
 Electrode wire diameter;
 Multiple electrode configurations.
2.6 Advantages
 High deposition rates (over 100 lb/h (45 kg/h) have been
reported);
 High operating factors in mechanized applications;
 Deep weld penetration;
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 Sound welds are readily made (with good process design and
control);
 High speed welding of thin sheet steels up to 5 m/min (16
ft/min) is possible;
 Minimal welding fume or arc light is emitted.
Practically no edge preparation is necessary · The process is
suitable for both indoor and outdoor works. · Distortion is much
less. · Welds produced are sound, uniform, ductile, and corrosion
resistant and have good impact value. · Single pass welds can be
made in thick plates with normal equipment. · The arc is always
covered under a blanket of flux, thus there is no chance of spatter
of weld.
2.7 Limitations
 Limited to ferrous (steel or stainless steels) and some nickel
based alloys;
 Normally limited to the 1F, 1G, and 2F positions;
 Normally limited to long straight seams or rotated pipes or
vessels;
 Requires relatively troublesome flux handling systems;
 Flux and slag residue can present a health & safety issue;
 Requires inter-pass and post weld slag removal.
.
2.8 Submerged Arc Welding Benefits
 Extremely high deposition rates possible
 High quality welds
 Easily automated
 Low operator skill required
25
Chapter 3
Methodology
3.1 Methodology
The base material employed in this study is 12.5 mm-thick Carbon

Steel A36 welded with AWS 5.17 filler material. The chemical
composition of the base material and filler material are shown in
Table 3.1. The selection of the filler material is based on the
mechanical properties and resistance to cracking in the weld. The
main process parameters in SAW welding are Arc current, Arc
voltage, welding speed and electrode stick-out, which are generally
considered for controlling quality.
In the present study, the effect of peak current, base current, and
pulse frequency on dilution and mechanical properties have been
studied. Trial runs were conducted by varying one of the process
parameters and keeping the others constant. The working range of
peak current, base current, and pulse frequency were explored by
inspecting bead appearance and the full penetration.
26
The range of the process parameters selected under the present

study and the constant process parameters are shown in Tables 3.2
respectively. In the present investigation, the Taguchi method was
employed to optimize the process parameters for maximizing the
mechanical properties. The number of process parameters
considered under this study is four, and the level of each
parameter is two. The degrees of freedom of all the four
parameters and their interactions are seven. Hence, L 8 (27)
orthogonal array is selected. Each condition of the experiment was
repeated twice to reduce the noise/error effects. The detail of the
selected orthogonal array is presented in Table 3.3.
27
Figure 3.1: Side view of specimen before welding

28
Figure 3.2: Scheme of welding with respect to rolling direction and

extraction of tensile Specimens
Figure 3.3: Dimensions of tensile specimen

29
3.1.1 Experimental procedure

All of the requirement procedure and standard in preparation
the specimens are follow ASTM IX standards. Specimens for tensile
and hardness testing were taken at the middle of all the joints. The
procedure in preparation experiments are listed below.
1. Carbon steel A36 plate were chosen as a material selection.

The sheet are then is cut to the required size as shown in
figure 3.1. The dimension of the sheet a little bit longer from
the actual size. The cutting process used is plasma cutting
machine
Figure 3.4: Plate Cutting
2. The sheet is cut into smaller size before send for milling .The
proposes of milling is to square and bevel the edges.
30
Figure 3.5: Square and Bevel
3. After getting the design size, two sheet are then were joint
together by butt joint method. The sheets to be welded were
kept on a copper backing bar and the end clamped together
to maintain the alignment and gap.
Figure 3.6: Backing plate
4. Prior to welding, the base metal sheets were cleaned with a

solution of NaOH and HNO3; wire brushed, degreased using
acetone, and finally preheated to 100°C.
31
Figure 3.7: Brushing process
5. Once done sheets are ready to be welded by Submerge Arc

welding machine. The sheets are welded base on Taguchi
design Orthogonal array method (L8 (27) as shown in table
3.3. Working range of parameter for all of the sheets are set
and control as shown in figure 3.2. All sheets were marked by
numbers to prevent from miss identifying
32
Fig. 3.8: Saw Machine Fig. 3.9: Saw

Display unit
Fig 3.10: wire stick out measured Fig. 3.11:

welding in progress
33
Fig. 3.12: Sample for sheet 5 Fig. 3.13:

Sample for plate 8
6. Band saw cutting machine were used to cut the roughly the
specimen size before sending to the milling machine to get
the precise size as shown in figure 3.3. To get the flat surface
the welding beads on the specimen were removed using
grinding machine.
34
Figure 3.14: Band saw cutting Figure 3.15:

Specimen sample
35
Fig. 3.16: Weld bead grinding Fig. 3.17:

Numbering process
7. The specimens were cut using milling machine to get the

throat radius as per required in design as shown in figure 3.3.
Fig. 3.18: Throat cutting Fig. 3.19:

Radius cutting
36
3.2. Mechanical properties
3.2.1 Tensile Strength
Maximum tensile strength was observed when the pulse frequency and pulse
current are on the higher side. High correlation coefficients indicate a good
relationship between the parameters and the observed property data. Maximum
tensile strength was observed when the pulse frequency and pulse current are on
the higher side. High correlation coefficients indicate a good relationship
between the parameters and the observed property data.
A tensile test helps determining,
1. Tensile properties such as tensile strength, yield point or yield strength
and modulus of elasticity.
2. Ductility of a weld. Two standard measurements of ductility are the
percent elongation and the percent reduction of area.
37
Fig. 3.20: Tensile Machine, Model Fig. 3.21: Tensile

progress
Hung Ta – 500T
Fig. 3.22: Specimen before testing Fig. 3.23:

Specimen after testing
38
3.2.1.1 Weld Metal Tensile Test
A transverse Tensile Test specimen is cut from a welded butt joint (at right angle to
the weld direction and is used to determine its transverse tensile strength. Reduced
transverse test specimens are not intended to give the tensile strength of the weld
metal, but Radius reduced specimens do occasionally.
In an all weld metal tensile test, the specimen is prepared from all weld metal. This
type of specimen is prepared by machining a groove in a plate of steel and then
completely filling the groove with deposited weld metal. The surrounding steel is
then machined away leaving a specimen of weld metal.
The purpose of such a test is to test
i. Electrodes for their suitability for the job concerned.

ii. The quality of deposited metal in welded joint.
3.2.1.2 Test Procedure
Tensile test is carried out by gripping the end of the specimen in a tensile testing
machine and applying and increasing pull on to the specimen till it fractures. During,
the test, the tensile load as well as the elongation of a previously marked gauge
length in the specimen is measured with the help of load dial of the machine and
extensometer respectively. These readings help plotting stress strain curve. After
39
fracture, the two pieces of the broken specimen are placed as if fixed together and
the distance between two gauge marks and the area measured.
3.2.2 Hardness Test

Micro-hardness tests were carried out on the welded samples with
a load of 15 g and a duration of 10 s using a Vickers digital micro-
hardness tester (make: Yata, model: HMT -IT). The micro-hardness
was measured at an interval of 0.15 mm across the weld, 0.5 mm
across the heat-affected zone, and 1 mm across the unaffected
base metal.
Fig. 3.24: Hardness - Yata HMT-IT Fig. 3.25: Specimen

testing
3.2.2.1 Procedure of Hardness Testing
Specimen is placed on the anvil; the hand wheel is rotated so that the specimen
along with the anvil moves up and contacts with the ball. The desired load is
40
applied mechanically (by a gear driven screw) or hydraulically (by oil pressure)
and the ball presses into the specimen. The diameter of the indentation made in
the specimen by the pressed ball is measured by the use of a micrometer
microscope, having a transparent engraved scale in the field of view. The
indentation diameter is measured at two places at right angles to each other, and
the average of the two readings is taken. The Brinell hardness number (BHN)
which is the pressure per unit surface area of the indentation in kg per square
meter is calculated as follows:
BHN = W / (π D / 2) (D – root of D 2 – d 2)
W is load on indenter, kg
D is diameter of steel ball, mm
D is average measured diameter of indentation, mm
3.2.2.1 Procedure for Measuring Hardness
a) Test piece is placed upon the machine. The machine dial is showing any
reading.
b) Hand wheel is turned, thereby raising the test piece up against the steel ball
indenter till the needle on the dial reads zero. This applies minor load
c) Major load is applied by pressing the crank provided on the right-hand side
of the machine (not shown).
d) Crank is turned in the reverse direction thereby withdrawing major load but
leaving minor load applied.
e) Hand wheel is rotated and the test piece is lowered.
At this stage, the hardness of the test piece material can be directly read from the
dial scale. Vickers Hardness Test in Vickers hardness test, a known load (P)
(from 1 to 120 kg) is applied for a specified time to the surface of the material
41
through a square base pyramid diamond having 136° between opposite faces.
The two diagonals of the resulting square indentation on the test piece are
measured with a micrometer microscope and averaged, (D, mm). The Vickers
hardness number is calculated as follows VHN = 1.854 P / D2 Before
conducting Vickers hardness test, the surface of the specimen should be flat and
of sufficient polish so that any remaining scratches do not cause difficulty in
locating the corners of the indentation when diagonals are measured. The
impression of Vickers indenter on the specimen being very small, peak (and not
average) values of hardness can be determined on the weld from root to face. In
the same length of the specimen, more hardness readings can be taken with
Vickers hardness test than with Brinell or Rockwell hardness tests
Micro-hardness survey in transverse to the weld direction of a

typical weld (P5) revealed 3 different regions, such as weld
center (WC), heat-affected zone (HAZ), and unaffected base
metal will finalist. Specimens for micro hardness tests (15-mm
width) were taken at the middle of all the joints. Micro-hardness
tests were carried out on the welded samples with a load of 500
gram and a duration of 10 s using a Vickers digital micro-
hardness tester (make: Yata, model: HT-9502. The micro-
hardness was measured at an interval of 0.15 mm across the
weld, 0.5 mm across the heat-affected zone, and 1 mm across
the unaffected base metal. The schematic sketch of the
hardness survey is shown in figure 3.4.
Fig. 3.26: Schematic sketch of hardness welding area

42
3.2.3 Deposition
. The position rate of a welding consumable (electrode, wire or rod)

is the rate at which weld metal is deposited (melted) onto a metal
surface. Deposition rate is expressed in kilogram per hour (kg/hr).
Deposition rate is based on continuous operation, not allowing for
the stop and start such as, electrode change over, chipping slag,
cleaning spatter, machine adjustment or other reasons
When welding current is increased so to does the deposition rate.

When electrical stick out is increased in case of GMAW and FCAW
the deposition rate will also increase. Deposition rate are
calculated by doing actual welding test and the following shows
the formula for measuring deposition rates.
Deposition rate = Weight of test plate after welding – Weight of

test plate before after welding ÷ Measured period of the time
(normally 60 seconds)
3.2.4 Microstructures
The observations of microstructures at the weld center are

considered for comparison in different welding conditions. The
microstructures at the central region submerge arc welding welds
using the experimental layout will be used to observed that
microstructures consists of dendrites and assume the dendrite arm
spacing equal to the grain size. Specimens for metallographic
observation were taken at the middle of all the joints. The
43
specimens were suitably sectioned, mounted in transverse

direction of the welding, mechanically polished according to
standard metallographic procedures, and etched using modified
Keller’s reagent (2 ml HF, 3 ml HCl, 20 ml HNO3 and 175 ml H2O).
Microstructures were observed and recorded using an optical
microscope.
Fig.3.27: Polishing Machine Model Fig. 3.28:

Polishing activity
Metaserv 2000
44
Fig 3.29.: Microscope Olympus

Model BX4M
3.2.4.1 Concept and Purpose
a) Macro etch examination
After preparing the specimen by polishing and etching, it is examined either by

the naked eye or by low power magnification up to X15. Macro examination
gives a broad picture of the specimen by studying relatively large sectioned
areas.
Macro examination reveals in welded specimen

45
i. Cracks
ii. Slag inclusion
iii. Blowholes
iv. Shrinkage porosity
v. Penetration of the weld
vi. The boundary between the weld metal and the base metal
b) Micro etches examination
After preparing the specimen by polishing and etching, it is examined under a

microscope at fictions from X20 to X2000. Micro etch examination involves
areas much smaller than those considered in micro etch examination and brings
out information that can never be revealed by macro examination.
Micro examination determine in a welded specimen
i. Cracks and inclusions of microscopic size

ii. Grain boundaries and solidification structures of weld metal, heat
affected zone and the base metal
iii. Distribution of micro constituents in the weld metal
3.2.4.2 Preparation of Test Specimen
a) The specimen shall be the full thickness of the material at the welded
joint and the weld reinforcement and penetration bead shall be left intact.
The specimen shall contain a length of the joint of at least 10 mm and
46
shall extend on each side of the weld for a distance that includes the heat
affected zone and some base metal portion.
b) Specimen after being cut from the plate is filled or ground to obtain flat
surface on the specimen.
c) Intermediate and fine grinding is carried out using emery paper of

progressively finer grades, i.e., of grades , 200 grit, 320 grit and 600 grit
(from coarse to fine)
d) Rough and fine polishing of the specimen is carried out on a rotating

polishing wheel. Fine polishing removes the scratches and very thin
distorted layer remaining on the specimen from the rough polishing
stage. (v) Etching. The specimen is then etched in order to make visible
the grain boundaries, heat affected zone, the boundary between the weld
metal and parent metal, etc. Etching imparts unlike appearances to the
metal constituents and thus makes metal structure apparent under the
microscope.
Etching is done either by
i. Immersing the polished surface (of the specimen) in the etching

reagent.
ii. Rubbing the polished surface gently with a cotton swab wetted
with the etching reagent.
3.2.4.3 Etching reagents
Given below are a few etching reagents

47
a) Hydrochloric Acid. The reagent contains equal parts by volume of

concentrated HCI and water. Specimen is immersed in this reagent at or
near the boiling point. This will usually enlarge gas pockets and dissolve
slag inclusions, enlarging the resulting cavities
b) Grain boundaries Nitric Acid. One part of concentrated nitric acid is
added to three parts of water by volume. The reagent may be applied to
the surface of the weld either with a glass stirring rod at room
temperature or the weld be immersed in boiling reagent provided the
room is well ventilated. This reagent is used on polished surfaces only to
show the weld metal zone as well as the refined zone. Nital contains 2CC
HNO3 Conc. + 98CC absolute methyl alcohol.
c) Ammonium persulphate. Mix one part of ammonium persulphate (solid)

to nine parts of water by weight. The reagent thus prepared is rubbed
vigorously on the surface of the weld with cotton saturated with this
reagent
d) Iodine and potassium iodide. One part of powdered iodine (solid) is

mixed with twelve parts of a solution of potassium iodide by weight. The
latter solution should consist of one part of potassium iodide to five parts
of water by weight. The reagent is brushed at room temperature on the
surface of the weld.
48
Chapter 4
Results and Analysis
4.1 Result for tensile test
Tensile Test Results
Average Average of
Specimens Sample 1 Sample 2 of Elongation
Tensile Elongation Tensile Elongation Tensile (mm)
Strength (mm) Strength (mm) Strength
(kN) (kN) (kN)
1 51.10 9.36 50.25 8.64 50.675 9.00
2 45.19 7.36 49.97 9.28 47.580 8.32
3 54.03 12.76 51.35 10.88 52.690 11.82
4 49.07 9.64 52.93 11.96 51.000 10.80
5 56.09 15.36 57.34 15.64 56.715 15.50
6 56.63 16.96 55.57 16.32 56.100 16.64
7 56.67 15.12 55.25 15.72 55.960 15.42
8 55.18 15.64 51.92 11.96 53.550 13.80
Base 52.58 19.52 51.93 18.76 52.255 19.14
Metal
Table 4.1: Result for Tensile Test

49
Figure 4.1: Tensile report for specimen 5
4.2 Result for Hardness test

50
Welding Area
Specimen Point Weld Average of HAZ Base metal
No. centre Hardness at weld centre (HV) (HV)
( HV)
1 199 130 106
1 2 196 202.67 127 117
3 213 124 105
1 201 129 117
2 2 198 201.33 140 113
3 205 137 122
1 188 128 113
3 2 203 195.33 128 116
3 195 120 110
1 200 133 125
4 2 198 197.67 142 121
3 195 134 119
1 156 119 130
5 2 153 154.67 120 123
3 155 125 125
1 172 116 114
6 2 165 168.67 125 122
3 169 130 125
1 156 120 118
7 2 170 163.33 121 120
3 164 125 115
1 186 127 120
8 2 176 176.67 125 114
3 168 120 117
Table 4.2: Result for Hardness Test

51
Figure 4.2: Load versus welding area graph
4.3 Results for Deposition
Weight of specimen
Specimen Process Deposition
No Weight before Weight Net weight time (kg/hour)
welding after (gram) (sec)
(gram) welding
(gram)
1 1756 1819.35 63.35 30 7.602
2 1759 1845.53 86.53 40 7.787
3 1757 1819.55 62.55 30 7.506
4 1749 1833.25 84.25 40 7.583
5 1755 1821.20 66.20 30 7.944
6 1758 1846.65 88.65 40 7.978
7 1750 1814.75 64.75 30 7.770
8 1760 1849.75 89.75 40 8.078
52
Table 4.3: Result for Hardness Test
Deposition = Weight after weld – Weight before weld

Process Time
= 1819.35 - 1756
30
= 2.111 gram/sec
Therefore,
2.111 gram/sec × [1 kg/1000 gram] × [3600 sec / 1 hour]
= 2.11 × 3600
1000
= 7.602 kg/hour
4.4 Experiment Data result

53
4.4.1 Example to find Tensile strength for Specimen P1
= 1 x [1 / 50.6752]
= 3.894 x 10 -4
Therefore, S/N ratio for Tensile = -10 Log 10 (LHB)
= -10 Log10 (3.894 x 10 -4)
= 34.096 dB
4.4.2 Example to find Hardness for Specimen P1
= 1 x [1 / 202.672]
= 2.435 x 10-5
Therefore, S/N ratio for Hardness = -10 Log 10 (LHB)
= -10 Log10 (2.435 x 10-5 )
= 46.136 dB
4.4.3 Example to find Deposition for Specimen P1
= 1 x [1 / 7.6022]
= 0.0173
54
Therefore, S/N ratio for Deposition = -10 Log 10 (LHB)
= -10 Log10 (0.0173)
= 17.619 dB
4.5 Micro Structure Result (100 um)
Figure. 4.3: Base metal Figure 4.4:

Specimen no.1
55
Figure 4.5: Specimen no.2 Figure 4.6:

Specimen no.3

Specimen no.5
56

Specimen no.7
Figure 4.11: Specimen no.8
4.6 Analyze using Taguchi Design

The MINITAB software are use to analyze the Data of Experiment as
mention as in table 4.4.
57
Main Effects Plot (data means) for Tensile

welding current welding voltage
54.0
53.5
53.0
52.5
Mean of Tensile
52.0
400 500 26 30
welding speed wire stick out
54.0
53.5
53.0
52.5
52.0
30 40 19 25
Figure 4.12 Main Effect Plot for Tensile
Main Effects Plot (data means) for Hardness

186.0
184.5
183.0
181.5
Mean of Hardness
180.0
400 500 26 30
welding speed wire stick out
186.0
184.5
183.0
181.5
180.0
30 40 19 25
Figure 4.13 Main Effect Plot for Hardness

58
Main Effects Plot (data means) for Deposite rate

7.85
7.80
Mean of Deposite rate

7.75
7.70
400 500 26 30
w elding speed wire stick out
7.85
7.80
7.75
7.70
30 40 19 25
Figure 4.14 Main Effect Plot for Deposite rate
Interaction Plot (data means) for SN ratios

B
35.0 26
30
34.8
34.6
SN ratios
34.4
34.2
34.0
33.8
400 500
A
Signal-to-noise: Larger is better
Figure 4.15: Interaction graph between A x B for Tensile

59

34.7 C
30
40
34.6
34.5
SN ratios
34.4
34.3
34.2
400 500
A
Figure 4.16: Interaction graph between A x C for Tensile

34.8 C
30
34.7 40
34.6
34.5
SN ratios
34.4
34.3
34.2
34.1
34.0
26 30
B
Figure 4.17: Interaction graph between B x C for Tensile

60

B
46.0 26
30
45.5
SN ratios
45.0
44.5
44.0
400 500
A
Figure 4.18: Interaction graph between A x B for Hardness

45.5 C
30
40
45.4
45.3
SN ratios
45.2
45.1
45.0
44.9
400 500
A
Figure 4.19: Interaction graph between A x C for Hardness

61

45.6 C
30
45.5 40
45.4
45.3
SN ratios
45.2
45.1
45.0
44.9
44.8
26 30
B
Figure 4.20: Interaction graph between B x C for Hardness

B
18.0 26
30
17.9
SN ratios
17.8
17.7
17.6
17.5
400 500
A
Figure 4.21: Interaction graph between A x B for Deposition rate

62

17.95 C
30
40
17.90
17.85
SN ratios
17.80
17.75
17.70
17.65
400 500
A
Figure 4.22: Interaction graph between A x C for Deposition rate

18.00 C
30
40
17.95
17.90
SN ratios
17.85
17.80
17.75
17.70
26 30
B
Figure 4.23: Interaction graph between B x C for Deposition rate

63
4.7 Analysis Result and Graph
The interaction graph between factor A x B, Ax C and B x C on Tensile are shown in

Table 4.15 Table 4.16 and Table 4.17 respectively. Therefore from the analysis data
we find out the maximum value of tensile ca be achieved if control factor are set at
B2 C1 A2 D1
Table A B A× B C A× C B×C D
1 34.424 34.294 34.105 34.641 34.424 34.650 34.521
2 34.529 34.659 34.293 34.314 34.529 34.295 34.433
Delta 0.105 0.365 0.127 0.327 0.105 0.355 0.088
Rank 5 1 4 3 6 2 7
Table 4.5 Tensile Analysis data

C2 D1 B1 A2
1 45.135 45.355 45.136 45.000 45.136 45.354 45.359
2 45.235 45.016 45.235 45.370 45.236 45.016 45.011
Delta 0.0187 0.342 0.0989 0.368 0.100 0.338 0.348
Rank 7 3 6 1 5 4 2
Table 4.6 Hardness Analysis Data

C2 A1 B1 D1
1 17.871 17.850 17.871 17.734 17.871 17.850 17.827
2 17.765 17.786 17.765 17.902 17.765 17.785 17.8084
Delta 0.106 0.064 0.106 0.168 0.106 0.065 0.0186
Rank 2 6 3 1 4 5 7
Table 4.7 Hardness Analysis Data

64
4.8 Optimization of parameter
1. To get the maximum tensile we need to set the machine

parameter as per result data which is Arc current is 500
amps; the Arc voltage is 30 volt; the welding speed is 30
cm/sec and the electrode sickout is 19 mm.
2. To get the maximum hardness need to set the machine

cm/sec and the electrode sickout is 19 mm
3. To get the maximum tensile we need to set the machine

cm/sec and the electrode sickout is 19 mm
Mechanical Properties Parameter Characteristics

Tensile ( kN) B2 C1 A2 D1
Hardness (HV) C2 D1 B1 A2
Deposition ( kg/hour) C2 A1 B1 D1
Table 4.8: Summary of the Result

65
Chapter 5
DISCUSION
Taguchi’s Method design on experiment is the best solution to get

optimum welding-process-parameter and their interaction. From
the experiment and testing data, its will show us the optimal levels
and their interaction of the factors for the mechanical properties It
was observed that the performance characteristics of the SAW
process, such as deposition rate, dilution and hardness, are
improved together by using the method proposed in this study.
66
Chapter 6
CONCLUSION
Factors such as arc current, arc voltage and welding speed and
their interactions play a significant role in the SAW process.
Taguchi’s experimental design strategy was applied to obtain
optimum welding-process-parameter combinations for each of the
performance criteria by maximization of deposition rate,
minimization of dilution and maximization of hardness.
Interestingly, the optimal levels of the factors for all the four
objectives happened to be different. The analysis was further
supplemented by a more rigorous statistical analysis known as
ANOVA. Identified factors and their interactions were validated
through a set of confirmation experiments. The optimum search for
welding process parameter values for the objective of
maximization of deposition rate and hardness and minimization of
dilution was formulated as a multiobjective, multivariable,
nonlinear optimization problem. It was observed that the
performance characteristics of the SAW process, such as
67
deposition rate, dilution and hardness, are improved together by

using the method proposed in this study.
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parameter on mechanical properties and optimization of
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2. Amar Patnaik, Sandhyarani Biswas, S.S. Mahapatra. (2007).
An evolutionary approach to parameter optimization of
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Int.J.Manufacturing, Research.
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(2007). Effect of welding processes on tensile properties of
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Regent Prentice Hall. ISBN 0-13-594300 0
9. William A.Bowditch, Kevin E.Bowditch Welding Technology
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Volume 6 .The Material Information ISBN 0-87170-382-3
11. http://www.weldingengineer.com/1saw.htm
12. http://en.wikipedia.org/wiki/Submerged_arc_welding#El
ectrode
13. http://www.journalamme.org/papers_vol27_2/27221.pd
f
14. http://www.ee.iitb.ac.in/~apte/ExcelTaguchi_1.htm
15. http://www.materialsengineer.com/SAW.htm
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7.htm
69
Appendix A
Graph 1: Test Report for Specimen 1
70
Appendix A
71
Appendix A
72

73
Appendix A
74
Appendix A
75
Appendix A
Appendix A
76

77
Appendix A
78
Appendix A
Graph 9: Test Report for Specimen Base plate
79
Appendix B
Table 1: Welding Procedure Specification (WPS)
80
Appendix B
Table 2 Double V-groove Butt joint
81
Appendix C
Table 1: Prequalifed PJP Groove Welded
82
Appendix C
Table 2: Legend for Table 1
83
Appendix D
84
Table 1: Prequalifed Base Metal- Filler Combination for Matching

Strength
85
Appendix D
Strength
86
Appendix D
Strength
87
Appendix D
Strength
88
Appendix E
Table 1: Prequalifed Minimum Preheat and Interpass Temperature

89
Appendix E

90
Appendix E

PSM 1 (Edited To PSM 2) - Repair

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SUBMERGE ARC WELDING EVOLUTION OF CARBON

ZAINAL ABIDDIN SHAH BIN MATTAR

A thesis submitted in fulfillment of the

FACULTY OF MECHANICAL ENGINEERING

candidature of any other degree.”

Name : ZAINAL ABIDDIN SHAH BIN MATTAR

Date : ............................................. ............................

To my beloved family and friends

The author would like to express deepest appreciation to supervisor, PM

Selection of process parameters has great influence on the quality of a

Pemilihan proses kimpalan memberi pengaruh yang besar terhadap kualiti

CHAPTER TITLE PAGE

2.5.2.2 Arc Voltage 15

4 RESULTS AND ANALYSIS

4.7 Analyze Result and Graph 53

TABLE NO. TITLE PAGE

3.1 Chemical composition of the base metal and filler 22

FIGURE NO. TITLE PAGE

3.15 Specimen sample 28

4.20 Interaction Graph between B x C for 51

Carbon SteelA36 steel is a standard steel alloy which is a common

Carbon steel plate is extensively used in heavy fabrication

satisfactory penetration, good deposition rate, and smooth spatter

contribution of each process parameter and their interaction in

1.2 Flow Chart of Project Planning

To find out the optimal welding process parameter of submerge arc

1.4.1 Taguchi method

Taguchi method is a new method of conducting the design of

Taguchi’s philosophy is an efficient tool for the design of high

logarithmic functions of desired output serve as objective functions

Where De, Di and Hr represent the response for deposition rate,

1.4.2 Minitab Software

Analysis of experiment data was carried out using MINITAB

1.4.3 Analysis of variance (ANOVA)

An ANOVA is an analysis of the variation present in an experiment.

2.1 Submerged Arc Welding (SAW)

The Submerged Arc Welding (SAW) process involves formation of

hopper. Remaining fused slag layers can be easily removed after

SAW is usually operated as a fully mechanized or automatic

There is virtually no restriction on the material thickness, provided

2.2 Submerge Processes

In the Submerged Arc Welding (SAW) process, schematically shown

Figure 2.1: SAW Process

flux can be recovered and reused after proper processing. The

Figure 2.2: Equipment for SAW

One of the great advantages of the SAW process is its adaptation

Figure 2.3: SAW Configurations

In addition, multiple welding heads can be included into the

position. Depending on material thickness, either single-pass, two-pass or

 Fused fluxes - produced by mixing the ingredients, then melting them in an

Figure 2.4: Wire and Flux Identification

Figure 2.5: Wire Size

Listed are some current and voltage ranges for commonly

Table 2.1: Wire & Current and Voltage

2.5.2 SAW process variables

2.5.2.1 Amperage/wire Feed Speed (WPS)

Figure 2.6: Amperage varied weld

Ampere and WPS are directly related to each other in that as

2.5.2.2 Arc Voltage

Figure 2.7: Voltage Varied Welds

The primary function of voltage is to control the shape of the

Excessively high arc voltage will:

2.5.2.3 Travel Speed