International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 12 Issue: 06 | Jun 2025
p-ISSN: 2395-0072
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ENHANCING THE EFFICIENCY AND QUALTY OF PIPELINE WELDING USING REGULATED METAL DEPOSITION (RMD) TECHNIQUES Vimal Kumar Chaudhary1, Shiv Kumar2 1M.Tech. (ME) Scholar, Department of Mechanical Engineering, Goel Institute of Technology and Management
Lucknow, Uttar Pradesh, India
2Assistant Professor, Department of Mechanical Engineering, Goel Institute of Technology and Management
Lucknow, Uttar Pradesh, India ----------------------------------------------------------------------***--------------------------------------------------------------------goods are initially designed as separate parts. To Abstract: The global demand for oil and gas continues
produce useful, dependable, and reasonably priced components, industries including automotive, aerospace, petrochemical, medical, culinary, and energy commonly need to combine materials of different sorts and thicknesses.
to rise, leading to increased construction of highstrength transmission pipelines, primarily using low alloy steel. Traditional welding methods such as Gas Metal Arc (GMA) and Gas Tungsten Arc (GTA) welding are widely used in pipeline fabrication. However, these techniques present challenges such as poor weld quality, high spatter, porosity, and low productivity, particularly due to a shortage of skilled welders. While GTA welding offers excellent quality for root passes, its low welding speed limits its suitability for mass production. To address these issues, advanced welding technologies are being explored, with Regulated Metal Deposition (RMD) emerging as a promising alternative. RMD offers smoother arc control, better weld quality, and faster operation, making it more accessible and efficient. This dissertation focuses on experimentally analyzing the effects of RMD welding parameters—namely welding current, voltage, and gas flow rate—on low alloy steel using metal-cored filler wires. Output responses studied include heat-affected zone (HAZ), depth of penetration (DOP), bead width (BW), and bead height (BH). A Taguchi L25 orthogonal array was used to design experiments, conducted on a Miller ‘Continuum 500’ machine. ANOVA was applied to assess the significance of each variable. Due to the conflicting nature of desired outcomes (low HAZ, BW, BH and high DOP), optimization of welding parameters is essential for achieving the best performance. This study aids in identifying optimal welding conditions for improved efficiency and weld quality in pipeline applications.
1.1 Gas Metal Arc Welding Process Developed in the 1950s, GMA welding is sometimes called Metal Inert Gas (MIG) or Metal Active Gas (MAG) welding. This method uses an electric arc to heat metals to their melting temperatures in order to connect them. In order to help the two base materials coalesce, a consumable filler wire is continuously supplied into the weld puddle using a welding gun shaped like a nozzle. An efficient inert environment, referred to as shielding, is produced around the welding area to protect the weld puddle from airborne pollutants. For shielding, gases like carbon dioxide, argon, helium, or different gas combinations are utilised. Fig. 1 [8–10] shows the welding region in enlarged view.
Keywords- Welding; GMA welding; RMD welding; Low alloy steel; Heat-affected zone; Depth of penetration; Bead width; Bead height; ANOVA; Optimization; Microstructure; Optical microscopy; SEM-EDX analysis; Micro-hardness; Tensile test; Impact test.
Fig. 1: An extended schematic image of the welding region [7]
1. INTRODUCTION
There are three primary methods for doing gas metal arc welding (GMAW): automated, machine, and semiautomatic. The welding gun is moved by a human operator in semiautomatic welding, while the apparatus manages the electrode feeding of the filler wire. Another
Technological developments are pushing the manufacturing and construction sectors to provide highquality, sustainable products at competitive pricing in today's fast-paced world. Real-world applications frequently call for assembly, even though the majority of
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