Regression-driven modeling and optimization of ultrasonic-assisted activated flux tungsten inert gas welding on AISI 316L

IF 2.5 4区材料科学 Q2 METALLURGY & METALLURGICAL ENGINEERING

Welding in the World Pub Date : 2025-06-04 DOI:10.1007/s40194-025-02090-7

Mahdi Mazloom Farsibaf, Mohammad Naser Sadraee Far, Ahmad Nourani, Farhad Kolahan, Sadegh Elhami

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Abstract

This study investigates the ultrasonic-assisted activated tungsten inert gas (UA-TIG) welding process, a promising technique for advanced manufacturing. The objective was to model and optimize UA-TIG parameters to enhance weld geometry, specifically achieving a high depth-to-width (D/W) aspect ratio. Activated by SiO₂ nanoparticles as flux, the process employed central composite design (CCD) to examine the influence of welding current, travel speed, and ultrasonic vibration amplitude across five levels. Bead-on-plate welding tests on AISI 316L stainless steel were supported by simulations to identify optimal ultrasonic zones. Using analysis of variance (ANOVA) and response surface methodology (RSM) for optimization, results revealed robust regression modeling with an error margin below 6%. Compared to tungsten inert gas (TIG) and activated flux TIG (A-TIG) methods, UA-TIG welding achieved a substantial D/W improvement, enhancing the ratio by 320% and 56%, respectively. UA-TIG welding also demonstrated the highest microhardness (210 Vickers) among the tested samples and effectively minimized heat affected zone (HAZ) width, showcasing its superior thermal control and weld quality. This work demonstrates UA-TIG’s effectiveness in achieving superior weld geometry with optimized parameters, indicating its potential for widespread application in precision welding.

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aisi316l型超声辅助活性焊剂钨极惰性气体焊接的回归驱动建模与优化

研究了超声辅助活性钨惰性气体（UA-TIG）焊接工艺，这是一种很有前途的先进制造技术。目的是建模和优化UA-TIG参数，以增强焊缝几何形状，特别是实现高深宽比（D/W）。在SiO2纳米颗粒作为助焊剂的激活下，采用中心复合设计（CCD）研究了焊接电流、移动速度和超声振动幅值在五个水平上的影响。对aisi316l不锈钢板上珠焊试验进行了仿真支持，确定了最佳超声区域。利用方差分析（ANOVA）和响应面法（RSM）进行优化，结果显示回归模型的稳健性，误差小于6%。与钨惰性气体（TIG）和活性助焊剂TIG （a -TIG）方法相比，UA-TIG焊接实现了显著的D/W提高，分别提高了320%和56%。在测试样品中，UA-TIG焊接还显示出最高的显微硬度（210维氏），并有效地减少了热影响区（HAZ）宽度，显示了其优越的热控制和焊接质量。这项工作证明了UA-TIG在通过优化参数实现卓越焊缝几何形状方面的有效性，表明其在精密焊接中的广泛应用潜力。

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来源期刊

Welding in the World METALLURGY & METALLURGICAL ENGINEERING-

CiteScore

4.20

自引率

14.30%

发文量

181

审稿时长

6-12 weeks

期刊介绍： The journal Welding in the World publishes authoritative papers on every aspect of materials joining, including welding, brazing, soldering, cutting, thermal spraying and allied joining and fabrication techniques.