Abstract—Submerged Arc Welding (SAW) is a common arc welding process which is used to join thick and heavy sections. The basic characteristics of this process are high deposition rate, ability to weld thick sections with ease and longer weld runs. The study of weld bead geometry is important, as it determine the stress carrying capacity of a weld. For the same reason, this paper highlights the analysis and study of process parameters: arc Voltage, welding current, travel speed and electrode extension, on the bead geometry response such as, bead height, bead width and bead penetration. Design Expert 8.0 with 4 factors, 5 levels, rotatable Central Composite Design. was used to develop relationship for predicting weld bead geometry, which enables to quantify the direct and interaction effects. Mathematical models prepared for the submerged arc welding of 16mm thick mild steel by using response surface methodology which co relate the process variables with the bead geometry characteristics then the adequacy of developed models were checked by using ANOVA technique. Using p-test, the significant terms were selected from the adequate models. The finally proposed models contains only the significant terms. Using the model, Graph drawn which shows the main and interaction effects of the process variables on weld bead geometry. The developed models can be used for prediction of important weld bead dimensions and control of the weld bead quality by selecting appropriate process parameter value.

Index Terms—Submerged arc welding, Central composite design, Response surface methodology, Arc voltage, Weld bead geometry

Cite: Uma Gautam and Mohd. Abbas, "Analysis of Weld Bead Geometry in Saw and Modeling Using CCD," International Journal of Mechanical Engineering and Robotics Research, Vol.2 No.3, pp. 168-181, July 2013.