Use of Response Surface Modeling in Prediction and Control of Flux Consumption in Submerged Arc Weld Deposits

Submerged arc welding is preferred over other methods of welding because of its inherent qualities like easy control of process variables, high quality, deep penetration, smooth finish, capability to weld thicker sections. Since the development of submerged arc welding process, welding engineers are striving for reduction in welding cost without compromise in the performance of the weld. Flux used in submerged arc welding contributes a major part towards welding cost. In the present work, the effect of operating voltage, welding current, welding speed and basicity index on flux consumption has been studied. Flux consumption for each bead was weighed. Response surface methodology was applied to derive mathematical models to predict and control the flux consumption within the range of the parameters. It was found that flux consumption increases with the increase in operating voltage, decreases with the increase in welding current and welding speed. It also increases with the increase in basicity index.