The document summarizes research on evaluating the metal inert gas welding process using activated flux on stainless steel 316L. It discusses:
- Literature reviewing various activated fluxes, materials, and input/output parameters in MIG, TIG, and other welding processes.
- The objectives of studying activated flux to improve weld penetration and productivity in MIG welding SS316L.
- The experimental setup using MIG welding machines and measuring penetration as the output parameter with welding current, voltage, and speed as inputs.
- An L9 orthogonal array to test the welding process without activated flux as a baseline.
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Optimizing SS316L Welds Using Activated Flux ANN Model
1. Evaluate The Metal Inert Gas Welding Process Using
Activated Flux On SS316L By ANN
1
Prepared by: Guided by:
Pavan Chaudhari Mr .J.D.Patel
M.E.(Production) HOD Mechanical
En.No:140650728014
2. 2
Outline
Introduction
Literature review
Summary of Literature review
Research gap from Literature review
Objective of present study
Experimental setup
Result sheet
Optimization Method
Result and discussion
Conclusion
Future Scope
Work plan
References
3. Introduction
3
Gas Metal Arc Welding (GMAW)
is an arc welding process that joins
metals together by heating them
with an electric arc that is
established between a consumable
electrode (wire) and the work
piece.
Basic Principle of GMAW
An arc is established between a
continuously fed electrode of filler
metal and the work piece.
After proper settings are made by
the operator, the arc length is
maintained at the set value.
4. 4
Activated flux
The flux ingredient which is inorganic compound (which can be used to produce
deep penetration and arc constriction) are available in variety of range and
compositions.
Oxide coating consists of iron, chromium, silicon, titanium, manganese, nickel,
cobalt, molybdenum and calcium are reported to improve weldability and
increase the welding speed.
The halogens, calcium fluoride and AlF2 have claim to constrict the arc and
increase weld depth of penetration .
Requirement of Activated flux
To improve weldability and increase the welding speed.
To constrict the arc and increase weld depth of penetration .
To reduce number of passes.
5. A-GMAW Process Description
5
Available literatures show that some of
the mechanisms, which play major role in
increase depth of penetration, are given .
6. Mechanism of Activated flux
6
Marangoni Effect.
Effect of arc constriction due to
negative ions.
Effect of arc constriction due to
insulating surface of flux.
Buoyancy force.
Electromagnetic force
7. Mechanism of Activated flux
7
Marangoni Effect Arc constriction due to
negative ions
Buoyancy force
Electromagnetic Force
8. 8
TITLE TIG welding with single-component fluxes
AUTHOR Modenesi Paulo J.
YEAR 2000
FLUX AlF3 , Al2O3 , Cr3O3 , CaF2 , Fe2O3 , Na2WO4 , SiO2 , TiO
MATERIAL 304 Stainless Steel
Input
Parameter
Gas Type- Argon Gas Flow l0 L/min
W.S. 20 cm/min Arc length 1±3 mm W.C. 200±300 A
Output
parameter
Penetration
Conclusion penetration can be obtained in A-TIG welding using activated Fluxes
LITERATURE REVIEW
9. 9
TITLE Mechanism and Optimization of Oxide Fluxes for Deep
Penetration in Gas Tungsten Arc Welding
AUTHOR LU SHANPING, FUJII HIDETOSHI,
YEAR 2003
MATERIAL 304 stainless steel
FLUX Cu2O, NiO, SiO2, CaO, Al2O3
Input
Parameter
Electrode type DCEN, W-2 pct ThO2 Diameter of electrode 1.6 mm
Shield gas Argon W.C. 160A W.S. 2 mm/s
Output
parameter
Penetration
Conclusion Cu2O has a narrow effective flux-quantity range for the deep penetration
10. 10
TITLE Electron Beam Welding with Activating Flux
AUTHOR Ruihua Zhang
YEAR 2006
MATERIAL stainless steels
FLUX SiO2 ,TiO2 ,Cr2O3 ,FS12
Input
Parameter
Welding speed 2-8mm/sec A.V 60kV Power 1500-2500W
W.C. 22.5-58.4 A Electron beam size 0.2-0.5mm
Output
parameter
Penetration
Conclusion Higher penetration Reduces B.W. at upper side, increase B.W. under side
11. 11
TITLE Effect of activating flux on arc shape and arc voltage in
tungsten inert gas welding
AUTHOR LI Qing-ming
YEAR 2007
MATERIAL Stainless Steel
FLUX SiO2, TiO2
Input Parameter W.C. 60-160A
Output
parameter
Penetration
Conclusion Sio2 flux, arc deflected towards the rear of arc moving direction
voltage increase with increasing in current so flux evaporated
12. 12
TITLE Gas tungsten arc welding of magnesium alloy using
activated flux-coated wire
AUTHOR Liu L.M., Cai D.-H.
YEAR 2007
MATERIAL magnesium AZ31B alloy
FLUX Mncl2, ZnO
Input Parameter Welding current 100 A Arc voltage 15–20 V
Travel speed 240 mm/min Wire feeding rate 360 mm/min
Output
parameter
Penetration
Conclusion Flux cored wire is more effective to increasing penetration.
40% Mncl2 and 60% Zno make deep penetration
13. 13
TITLE Marangoni convection and weld shape variation in A-TIG welding process
AUTHOR Xu Y.L. , Dong Z.B., Y.H. Wei, C.L. Yang
YEAR 2007
MATERIAL Nimonic 263 alloy
FLUX TiO, TiO2, Ti2O3
Input Parameter W.C. 150 A W.S 1.5 mm/sec
A.V. 10 V
Output
parameter
Penetration strength
Conclusion Flux on the top of the weld bead increase the penetration, effects of
arc constriction on the weld shape is very small. Reversed marangoni effect
14. 14
TITLE Effects of shielding gas composition and activating flux on GTAW weld
ments
AUTHOR Huang Her-Yueh
YEAR 2009
MATERIAL 304 Stainless steel
FLUX MnO2, ZnO
Input Parameter W.S. 75mm/min , W.C. 125A , Arc voltage 13-17 V
Shielding gas nitrogen 2.5-10 vol.% , Flow rate 20 µL/min
Output
parameter
Penetration
Conclusion Nitrogen additions to an argon base gas will increase the heat input, heat to
be transferred into specimens by the arc and consequently produced deep
penetration.
15. 15
TITLE Effects of activating flux on the welded joint characteristics in Gas metal arc
welding
AUTHOR Huang Her-Yueh
YEAR 2010
FLUX Fe2O3, SiO2, MgCO3
MATERIAL 1020 carbon steel
Input Parameter Arc voltage 20-23 V , W.C. 180-220 A
W.S. 346-454mm/min
Output
parameter
Penetration , tensile strength
Conclusion activating flux aided GMAW increased the weld area and penetration and
tended to reduce the angular distortion of the weldment.
17. 17
TITLE Research on the Activating Flux Gas Tungsten Arc Welding and Plasma
Arc Welding for Stainless Steel
AUTHOR Huang Her-Yueh
YEAR 2010
MATERIAL 304 stainless steel
FLUX TiO2 , SiO2, Cr2O3, MoO3
Input Parameter W.C. 75-100-125A W.S. 150 mm/min Shielding gas -Ar,
Gas flow rate 10L/min, 17.5L/min Plasma gas flow rate- 0.7L/min
Output
parameter
Penetration
Conclusion Both GTAW and PAW with activating flux produced a
substantial increase in the depth of penetration
18. 18
TITLE Estimation and optimization of depth of penetration in hybrid CO2 LASER-
MIG welding using ANN-optimization hybrid model.
AUTHOR Ghosal Sujit, Chaki Sudipto
YEAR 2010
MATERIAL 5005 Al–Mg alloy
Input Parameter Power P W, Focal distance F mm , Torch angle A deg.
Distance between the laser and welding torch S mm
Output
parameter
Penetration
Conclusion Output better than regression model, predicting, and optimizing operational
parameters of any experimental study with single output by running only one
program under MATLAB7.0
19. 19
TITLE Performance of activated TIG process in austenitic stainless steel welds
AUTHOR Tseng Kuang-Hung
YEAR 2011
FLUX MnO2, TiO2, MoO3, SiO2, Al2O3
MATERIAL 316L stainless steels
Input Parameter Weld current 200A Travel speed 150mm/min
Diameter of electrode 3.2mm Arc voltage 11-19V
Shielding gas - Pure argon Gas flow rate 10L/min
Output
parameter
Penetration
Conclusion fluxes produced a significant increase in weld depth and a decrease in bead
width
21. 21
TITLE Effect of activated TIG flux on performance of dissimilar welds between
mild steel and stainless steel
AUTHOR Cheng-Hsien Kuo, Tseng Kuang-Hung , Chang-Pin Chou
YEAR 2011
FLUX CaO, Fe2O3, Cr2O3, SiO2
MATERIAL JIS G3131mild steel and SUS 316L stainless steel
Input Parameter Weld current 200A Travel speed 150mm/min
Diameter of electrode 3.2mm Gas flow rate 12L/min
Output
parameter
Penetration
Conclusion SiO2 powder gives the greatest improvement in joint penetration
22. 22
TITLE Study of the characteristics of duplex stainless steel Activated Tungsten inert
gas welds
AUTHOR Chern Tsann- Shyi
YEAR 2011
FLUX TiO2, MnO2, SiO2, MoO3, Cr2O3
MATERIAL 2205 stainless steels
Input Parameter W.C. 200 A W.S. 150 mm/min
Diameter of electrode 3.2 mm Shielding gas Pure argon
Gas flow rate 10L/min
Output
parameter
Penetration, mechanical strength
Conclusion TIG welding with SiO2 flux produced a full joint penetration and the greatest
weld depth-to-width ratio.
23. 23
TITLE Mechanical properties and microstructures of 6082-T6 joint welded by twin
wire metal inert gas arc welding with the SiO2 flux
AUTHOR Y. Ruan
YEAR 2012
FLUX SiO2
MATERIAL 6082-T6 Al-alloy
Input Parameter Arc Voltage 19-21 V W.C. 210-220 A , W.S. 120cm/min
Output
parameter
Penetration
Conclusion 26% deeper penetration than without using activated flux
24. 24
TITLE Optimization of laser welding process parameters for super austenitic
stainless steel using artificial neural networks and genetic algorithm
AUTHOR Sathiya P. , Panneerselvam K., Abdul Jaleel M.Y.
YEAR 2012
MATERIAL 904L super austenitic stainless steel
Input Parameter Beam power 3-3.5 kW , Travel speed 2-3 m/min
Focal position 0 - (-2)mm
Output
parameter
Tensile strength, Bead width, Depth of penetration
Conclusion Relationship between the input and output parameter through ANN
25. 25
TITLE Experimental investigation on mechanism and weld morphology of activated
TIG welded bead-on-plate weldments of reduced activation ferritic/martensitic
steel using oxide fluxes
AUTHOR Vora Jay J., Badheka Vishvesh J.
YEAR 2015
MATERIAL RAFM Steel
FLUX Co3O4 , CuO ,HgO, MoO3
Input Parameter W.C. 200 A Shielding gas Ar , 10-12L/min
W.S. 100mm/min Electrode extension 5-6mm
Output
parameter
Penetration
Conclusion Continuous penetration was achieved with the use of fluxes Co3O4and CuO,
Reversed Marangoni effect was to be present as a depth enhancing
mechanism
26. 26
TITLE Effect of activating fluxes on weld bead morphology of P91 steel bead-on-
plate welds by flux assisted tungsten inert gas welding process
AUTHOR Dhandhaa Kamal H., Badheka Vishvesh J.
YEAR 2015
MATERIAL P91 Steel
FLUX CaO, Fe2O3, TiO2, ZnO, MnO2 and CrO3
Input Parameter W.C. 200 A , Shielding gas Ar , Gas flow rate 10-12L/min,
Dia.of electrode 2.9mm , W.S. 100mm/min, Electrode gap 2-3mm
Output
parameter
Penetration
Conclusion increase in weld penetration and the decrease in bead width with the use of the
activating fluxes.
28. Research gap from Literature review
28
It is obvious from the literature review that, most of researches worked on
TIG,PAW,EBW using different activated flux but few work has been done
on GMAW process yet so there is a scope of it.
The less work has been done for increasing its penetration as well as
strength on SS316L yet.
Based on Research paper activating flux is play noticeable effective for
GMAW process to increase penetration as well as strength.
Activating flux is most effective for GMAW process to increase penetration
as well as strength
29. 29
Objective of Present study
To improve the penetration of welding joint.
To minimize number of passes of weld and hence increase productivity.
To find out the best types of activated flux which can give the better
performance for this process.
30. 30
Experimental setup
Table -1 Specification of PROSTAR MIG 350 welding machine
SPECIFICATION PROSTAR MIG 350
Mains supply, Ph x V 3 x 415
Open circuit voltage DC (Max) 69 V
Welding current range
Welding voltage range
Frequency
40-350 A
16-31.5V
50Hz
Shielding gas Ar
Type of cooling Forced Air
Weight 40kg
Table 2- Specification of PROSTAR WF 60 MIG welding machine
SPECIFICATION WIRE FEEDER MACHINE
Drive system DC motor
Wire feed speed 1 – 24 m/min
Wire diameter
Weight
0.8-1.6mm
7kg
32. 32
Table 3 Chemical Composition of SS 316L
Table 4-Mechanical properties of SS 316L
Element Content (%)
Moly 2.060
Cr 16.210
Ni 10.400
Mn 1.300
Si 0.240
C 0.018
P 0.039
S 0.003
Properties Metric
Density 8000k g/m3
Tensile strength 485 MPa
Yield strength 170 MPa
Elastic modulus 193 GPa
Elongation 40%
33. 33
Table 5 Process parameter
PROCESS PARAMETER CONSTANT PARAMETER
Welding Current (A) Electrode size (mm)
Active Flux Shielding Gas
Arc Voltage (V)
Welding speed (mm/min)
Table 6 Input Parameter
NO Factor Level 1 Level 2 Level 3 Unit
1 Arc Voltage 20 22 24 Voltage
2 Welding current 150 180 200 Ampere
3. Welding speed 150 170 180 mm/min
4. Active Flux SIO2 Cr2O3 _ _
46. 46
Introduction to ANN
•Useful networks which contain only one layer, or even one
element, most applications require networks that contain at
least the three normal types of layers - input, hidden, and
output.
•The layer of input neurons receives the data either from
input files or directly from electronic sensors in real-time
applications.
•The output layer sends information directly to the outside
world, to a secondary computer process, or to other
devices such as a mechanical control system.
47. 47
•Between these two layers can be many hidden layers.
These internal layers contain many of the neurons in various
interconnected structures.
•The inputs and outputs of each of these hidden neurons
simply go to other neurons
52. 52
• When the programme run its generate 768 different location
of the different set of parameter. Tool process on the all this set
of different parameter and gives the best location of the
parameter set.
Here, range of input parameter :
Welding current 150:2:200 Welding speed 150:2:180
Arc voltage 20:2:24
Now the location generate in the programme are:
[150 150 20] [150 150 22] [150 150 24] [150 152 20] [150 154
22]............................
In this way all the location are generate for set of parameter.
54. 54
No flux case which indicate with red colour. From graph study
penetration is up to 3mm in starting parameter set but after it suddenly
fall down up to 2mm this fluctuation in this case occurred when the
voltage value is increased but when current and welding speed increase
its flow up the graph line give affective result.
Sio2 which indicate the blue colour, here penetration value is highest but
in further experiments it is gradually goes to down. welding speed and
welding current are mainly affect on the penetration.
Cr2o3 which indicate with the black colour, in this case penetration has
the higher consistency. There is no fluctuation in this case.
56. 56
No flux case show in red colour, here fluctuation in hardness in occurred.
Increased value of voltage made reduction in hardness of the weld and
its gradually reduced. welding speed make some changes in hardness.
Sio2 which indicate the blue colour, here hardness have higher value. In
compare too other there No fluctuation in is occurred. So that flux
increase the hardness. There is no change in metallurgy of the weld
specimen.
Cr2o3 which indicate the black colour, with compare to all above
experiment result this flux gives high penetration but, in case of hardness
it is after the Sio2 due to higher heat input at the weld point which make
the chemical effect on the material. The metallurgy structure affected by
the weld parameter and changes in the mechanical property of
the weld material.
57. 57
CONCLUSION
•This work has focused on the effect of Active flux on gas welding. Here, we
have select three various input parameter like welding speed, welding
current and arc voltage.
•The experiment had been done as per DOE, and two output result are
consider for this work, which are weld penetration and Hardness
•Active flux have play a noticeable effect on penetration of the weld plate
,which tested by Macro structure Examination and Hardness test.
• The output result of the experiment optimization by the ANN in MATLAB
which conclude that both flux give higher Penetration ,but sio2 flux has
higher consistency with both output weld penetration and Hardness of
material.
•With a visual inspection on the set of experiment, we had noticed that Arc
constriction is the main mechanism for the higher penetration.
58. 58
FUTURE SCOPE
Further study on this thesis with changing in the flux
powder or mixing the various flux.
Experiment possible will be with the change in welding
current, welding speed, arc voltage.
If we will change the size of the electrode its also effect
on the welding quality.
Experiment will be done with the change the material.
60. REFERENCE:
1.. Modenesi Paulo J, EustaAquio R. ApolinaArio, Iaci M. Pereira (2000)”TIG welding with single-component Fluxes”,Materials
Processing Technology 99, 260-265.
2. Lu Shanping, Fujii Hidetoshi, Hiroyuki Sugiyama,and Kiyoshi Nogi(2003),” Mechanism and Optimization of Oxide Fluxes for Deep
Penetration in Gas Tungsten Arc Welding”, Metallurgical And Materials Transactions A, 34A .
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4. Qing-ming , WANG Xin-hong, ZOU Zeng-da, WU Jun. (2007) , ” Effect of activating flux on arc shape and arc voltage in tungsten inert
gas welding” ,Trans. Nonferrous Met. Soc. China I7, 486-490.
5. Liu L.-M., Cai D.-H. , Zhang Z.-D. (2007)” Gas tungsten arc welding of magnesium alloy using activated flux-coated wire” Scripta
Materialia 57 , 695–698.
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process”,Theoretical and Applied Fracture Mechanics 48 ( 178–186)
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(2404–2409)
8. Huang Her-Yueh,(2010)” Effects of activating flux on the welded joint characteristics in gas metal arc welding”, Materials and Design
31, (2488–2495).
60
61. 9. Huang Her-Yueh,(2010)” Research on the Activating Flux Gas Tungsten Arc Welding and Plasma Arc Welding for Stainless
Steel”, Met. Mater. Int., 16, No. 5 pp. 819~825.
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using ANN-optimization hybrid model” Int J Adv Manuf Technol ,47,1149–1157
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Materials Processing Technology 211, (503–512)
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welds between mild steel and stainless steel”, Key Engineering Materials,479,74-80.
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welded by twin wire metal inert gas arc welding with the SiO2 flux”, Materials and Design 35 , (20–24)
15. Sathiya P., Panneerselvam K., Abdul Jaleel M.Y(2012)” Optimization of laser welding process parameters for super austenitic
stainless steel using artificial neural networks and genetic algorithm” Materials and Design ,36 , 490–498
16. Vora Jay J., Badheka Vishvesh J.,(2015),” Experimental investigation on mechanism and weld morphology ofactivated TIG
welded bead-on-plate weldments of reduced activationferritic/martensitic steel using oxide fluxesJ”, Journal of Manufacturing
Processes, 356.
17. Dhandha Kamal H. ,Badheka Vishvesh J.(2015)” Effect of activating fluxes on weld bead morphology of P91 steel bead-on-
plate welds by flux assisted tungsten inert gas welding process” Journal of Manufacturing Processes, 17 , 48–57
61