Optimization of Welding Process Parameter for Gap Response in Aluminum GMAW Using Taguchi Method

A gap is generated in the weld joint due to dimensional error of welded parts and thermal deformation aluminum alloy’s gas metal arc welding (GMAW) process alloy. The optimum conditions corresponding different gaps are required field. In this study, were optimized using Taguchi’s design experiment method response gaps. Al5083-O with a thickness 4.0 mm was used as base material, GMAW performed on T-fillet joints. An alternating current (AC) pulse for process, sizes. Three levels wire feed rate (WFR), electrode negative ratio (EN ratio), teaching point (T.P) selected parameters, 3 sizes (0, 0.5, 1.0 mm) noise factors. Other fixed at speed 40 cm/min, work angle degrees, push 10 contact tip distance (CTWD) 15 mm, shielding 100 % Ar. such leg length, penetration depth, throat measured cross-section. maximum size that satisfies minimum heat input target value. Based signal-to-noise analysis, WFR, EN ratio, T.P optimal 11 m/min, 20 %, 0 respectively.