T. Kannan

Effects of flux cored arc welding parameters on pitting corrosion resistance of duplex stainless steel clad metals

Abstract Most engineering applications require both high strength and corrosion resistant materials for long reliability and performance. This can be achieved by cladding the surface of steel with a metallurgically compatible corrosion resistant alloy. In recent years, duplex stainless steel has been extensively used for weld cladding. It has excellent pitting and crevice corrosion resistance, high yield strength, good toughness and weldability. During cladding, pitting resistance may be compromised by the formation of intermetallic precipitates, or by excessive precipitation of secondary austenite in the surface regions. Redistribution of alloying elements as a result of such transformations may lead to local reductions in pitting resistance. This may result from the dilution of the filler metal with the base metal and the heat input during cladding. Hence, control of dilution and heat input is very important to maintain the required pitting corrosion resistance. The present paper highlights an experimental study and analysis of various welding parameters influencing PREN and pitting potential in duplex stainless steel cladding deposited by flux cored arc welding (FCAW). Pitting resistance equivalent number (PREN) was found to decrease with increased welding current and welding speed and to increase with increased welding angle and tip to workpiece distance. Pitting potential increased with increased welding current, and tip to workpiece distance and heat input during cladding, and decreased with increased welding speed and welding angle.

Optimization of GMAW Process Parameters Using Particle Swarm Optimization

To improve the corrosion-resistant properties of carbon steel cladding process is usually used. It is a process of depositing a thick layer of corrosion resistant material-over carbon steel plate. Most of the engineering applications require high strength and corrosion resistant materials for long-term reliability and performance. By cladding, these properties can be achieved with minimum cost. The main problem faced in cladding is the selection of optimum combinations of process parameters for achieving quality clad and hence good clad bead geometry. This paper highlights an experimental study to optimize various input process parameters (welding current, welding speed, gun angle, contact tip to work distance, and pinch) to get optimum dilution in stainless steel cladding of low-carbon structural steel plates using gas metal arc welding (GMAW). Experiments were conducted based on central composite rotatable design with full-replication technique and mathematical models were developed using multiple regression method. The developed models have been checked for adequacy and significance. Using particle swarm optimization (PSO) the parameters were optimized to get minimal dilution.

Effects of Gas Metal Arc Welding Parameters on Weld Deposit Area of Stainless Steel Claddings

Weld cladding is a process of depositing a thick layer of a corrosion resistance material over carbon steel plate to improve corrosion resistance properties. The main problem faced in cladding is the selection of optimum combination of process parameters for achieving the required weld deposit area. This paper highlights the effects of various input process parameters on weld deposit area in stainless steel cladding of low carbon structural steel plates using gas metal arc welding. The experiments were conducted based on central composite rotatable design with full replications technique and mathematical model was developed using multiple regression method. The developed mathematical model has been checked for its adequacy and significance. This mathematical model is very useful for predicting the weld deposit area.

Estimation of Optimum Dilution in the GMAW Process Using Integrated ANN-GA

To improve the corrosion resistant properties of carbon steel, usually cladding process is used. It is a process of depositing a thick layer of corrosion resistant material over carbon steel plate. Most of the engineering applications require high strength and corrosion resistant materials for long-term reliability and performance. By cladding these properties can be achieved with minimum cost. The main problem faced on cladding is the selection of optimum combinations of process parameters for achieving quality clad and hence good clad bead geometry. This paper highlights an experimental study to optimize various input process parameters (welding current, welding speed, gun angle, and contact tip to work distance and pinch) to get optimum dilution in stainless steel cladding of low carbon structural steel plates using gas metal arc welding (GMAW). Experiments were conducted based on central composite rotatable design with full replication technique, and mathematical models were developed using multiple regression method. The developed models have been checked for adequacy and significance. In this study, artificial neural network (ANN) and genetic algorithm (GA) techniques were integrated and labeled as integrated ANN-GA to estimate optimal process parameters in GMAW to get optimum dilution.

Optimization of Flux Cored Arc Welding Process Parameters Using Particle Swarm Optimization Technique

In weld cladding applications, most of the engineers are often facing the problem of optimum selection of input process parameters to achieve the required dilution. This problem can be solved by optimizing the process parameters. This paper focuses on an optimization of flux cored arc welding process parameters, which are used for deposition of duplex stainless steel on low carbon structural steel plates. Experiments were conducted based on central composite rotatable design and mathematical models were developed using multiple regression method. Further, an optimization of percentage dilution was carried out using particle swarm optimization technique. A computer program was developed using C language for computation of algorithm. It is highly reliable, adoptable, very user friendly and it can be extended to other welding processes such as GMAW, GTAW, Robotic Welding,etc.