Box-Behnken design of quadratic model for Gas Metal Arc Welding (GMAW) and optimization analysis on desirability function

Gas Metal Arc Welding (GMAW) is one of those welding processes which is increasingly being used in many varieties of fabrication and manufacturing industries due to high production rate and ease of work such as fewer fumes/smoke and less time chipping slag. Important parameters which affect GMAW process are amperage, arc length, wire feed speed, welding speed and welding voltage. In this paper, we have focused and studied important controllable factor’s effects on depth of penetration, deposition efficiency, bead width and bead reinforcement to find best weld during welding in mobile or outdoor welding shop in stress and overloaded conditions by Box-Behnken design of quadratic model for GMAW process and optimization analysis on desirability function. Quality of welds is defined as "the level of perfection that welds exhibit pertaining to the entire volume of weldment as well as to the profile of weld surface appearance". With reference to quality weld definition as defined above, the study is performed to find out the best welding condition whereas best weld is the weld with deposition efficiency value as larger the best, depth of penetration value with "larger the best", bead width value "nominal the best", discontinuities number per weld’s count value "smaller the best". Productivity in term of quality is defined as an optimum blend of parameters which inevitably develop minimum or no defect then the process will result in high productivity. For given certain material and similar welding circumstances, our analysis has found the most optimal factor’s values for the similar condition of field data. This study will contribute welding research work in terms of points as described, firstly to enhance the knowledge of welding process and analysis by utilizing DOE along with desirability function, secondly ability to provide narrow window of weld process parameter to produce the quality weld and thirdly to study the GMAW process for mobile welding shop in the toughest condition such as the windy and dusty environment.