Effect of Welding Process Parameters on Leg Length and Development of Mathematical Model Using RCS 450 Steel

MIG (Metal Inert Gas) welding, also known as MAG ( Metal Active Gas ) and in the USA as GMAW ( Gas Metal Arc Welding), is a welding process that is now widely used for welding a variety of materials, ferrous and non ferrous. The essential feature of the process is the small diameter electrode wire, which is fed continuously into the arc from a coil. As a result this process can produce quick and neat welds over a wide range of joints. HSLA Steel (high strength low alloy steel) is a type of steel alloy that provides many benefits over regular steel alloys. In general, HSLA alloys are much stronger and tougher than ordinary plain carbon steels. They are used in cars, trucks, cranes, bridges and other structures that are designed to handle a lot of stress, often at very low temperatures. The various welding parameters such as current, voltage and arc length are varied on RCS 450 steel (alloy steel) and the effect of these parameters are studied on leg length and strength of a single transverse fillet weld using MIG welding. Mathematical model has been developed for relating leg length, current, and voltage and arc length. The Leg length is measured using a vernier scale and then it is compared with the calculated value of leg length that is obtained from the mathematical model. The Mathematical Model is developed using excel software and minimum value of R2is considered to be the fittest model. RCS 450 is used as material owing to its application in fabrication industry. The material dimension is 70mmx50mmx8mm , and 30 such samples are cut using a plasma machine. MIG A convenient way to evaluate the performance of mathematical equation in presenting the system under investigation is through the concept of response surface methodology. It is assumed that there exit some functional relationship such as:- Y = f ( X1,X2,X3). Where Y is the leg Length. X1 is the welding current. X2 is the welding voltage. X3 is the arc length. Y is the leg length.