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International Research Journal of Engineering and Technology (IRJET)

e-ISSN: 2395-0056

Volume: 12 Issue: 12 | Dec 2025

p-ISSN: 2395-0072

www.irjet.net

Process parameter optimization of submerged arc welding process Dr B.P. Kurpatwar SPPU , M.P. Patil SPPU Assistant professor, Department of mechanical engineering, Adul’s Technical campus, Chas, Ahilyanagar, India ---------------------------------------------------------------------***--------------------------------------------------------------------2 Qualities of weld deposited are determined by Abstract - The work has been considered for Sub merged following arc welding to determine process parameters with weld bead properties. weld bead that determines its mechanical qualities include the heat affected zone, the width of the weld bead, the area of penetration and the height of the reinforcement. Any welding technique can only be used effectively if associated criteria that affect the quality of the weld are understood. The size of the weld bead, mechanical characteristics, temperature distribution, and microstructural alterations are all factors in the weld quality. The primary composite design technique of response surface methodology is used to generate mathematical modelling of the impact of heat transfer on the properties of the weld bead during the SAW process. Plotting on the mean value, the scatter and contour plots show good consistency

Parameters  Welding current  Welding arc voltage  Electrodes stick out  Grade of wire  Travel speed  Size of electrode  Flux layer depth  Wire feed rate

3 WELDING PARAMETER AND ITS LEVEL Table 1Welding parameter and its level

Key Words: SAW, Taguchi method, Optimization, S/N ratio, ANOVA, welding parameters, Design

Level

1. INTRODUCTION In the current manufacturing period, a product's value in the market is largely determined by its quality, and all manufacturing firms must make each product in a costeffective way without sacrificing quality. Welding is the permanent connecting technique used in the fabrication industry. It is excellent, reasonably priced, and far faster than alternative methods like casting and riveting. The benefits of using SAW to fabricate circumferential joints in boilers, pipes, and pressure vessels are deep penetration, high deposition rate, fast speed, and exceptional surface quality. SAW is also used to develop parts and overlap with stainless steel for rail car wheels, mining, construction, and agricultural equipment, as well as rollers for continuous casting steel. The bead's geometry determines the quality of the weld. The important characteristics of weld bead geometry are the depth of penetration, height of reinforcement, and width of the weld bead. Therefore, it is imperative to develop a mathematical model based on the input setup parameters in order to evaluate the quantitative value or relationship between them and the weld bead properties in submerged arc welding. The input setting parameters, such as welding current, welding voltage, welding speed, and nozzle to plate distance, define the sound weld shape. Submerged arc welding is preferred due to its high melting efficiency, high production rate, ease of robotization, and minimal operator skill requirements. Scientists and researchers working in the fields of SAW and various aspects of the fusion welding process have produced a variety of works that have been discussed.

Impact Factor value: 8.226

Parameter Welding Current (AM)

355

430

480

Voltage

Speed

250

275

300

Electrode stick out

Test specimen EXPERIMENTAL SET-UPS       

Welding Records Welding process: SAW Welding Position: 1G Material: S355J0 Electrode Flux: EM12K+7A5 Diameter: 4.00mm Size of test plate: 20 X 300 X 500

Figure 1 : saw Welding

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