Study the Effect of CO2 Mag Welding Process Parameters on the Heat Input and Joint Geometry Dimensions Using Experimental and Computational Methods

Abstract

In this paper, predicted models for heat input and joint geometry dimensions after CO2- MAG welding process have been developed. Before welding, steel specimens were first prepared and then butt welded using electrode wire melted and supplied into the molten pool by applying heat input continuously. Weld bead dimensions were first measured, and then the results were analyzed to check the adequacy of the models by Response Surface Method using DOE technique. These models were found capable of predicting the optimum performance dimensions required for the joint geometry in terms of weld bead width, reinforcement height and penetration. The obtained results indicated that the heat input depends on voltage, wire feed speed and gas flow rate, while for the weld bead dimensions; the gas flow rate has less effect. A comparison between the experimental and predicted results was made, and a good agreement was found between them.