Modelling of Adv SAW For Dilution Reduction Sunil Pandey IIT Delhi 10

International Journal on Mechanical Engineering and Robotics (IJMER)
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ISSN (Print) : 2321-5747, Volume-2, Issue-2,2014
42

Modelling and optimization of advanced submerged arc welding
process for stainless steel cladding

1
Hari Om,
2
Sunil Pandey

1
Associate Professor, Department of Mechanical Engineering, YMCA University of Science & Technology, Faridabad -
121006 (India),
2
Professor, Department of Mechanical Engineering, Indian Institute of Technology, Delhi -110016 (India),
Email:
1
hariohm2001@gmail.com,
2
profsunilpandey@gmail.com

Abstract- Industries involved in surfacing operations use
various fusion welding especially arc welding processes.
These operations demand high deposition rates but at low
penetration values in the base metal. Conventional SAW,
besides its high deposition characteristics, employs high
values of welding current and is not many times favoured
for surfacing due to high degree of dilution of surfacing
alloys with base metal. This limits the use of SAW because
high dilution deteriorates intended benefits of surfacing.
Advanced submerged arc welding (ASAW) process, which
was developed in welding research laboratory at IIT Delhi
in the year 2004, provides a solution for the above. The
present work studies the effect of various parameters of the
process on the weld bead width, reinforcement, penetration
and percentage dilution by developing mathematical
models for each. Optimization of this relatively new
process for getting minimal dilution required for surfacing
has also been done.
Key words: Advanced submerged arc welding, weld
overlay cladding, dilution, RSM, central composite design,
I. INTRODUCTION
In some engineering applications, components and
equipment have to be operated under abnormal
atmospheric conditions such as elevated temperature or
highly corrosive environments. This requires
components to be corrosion and/or heat resistant. Some
applications demand high wear resistance of the
components. The adversity of service conditions limits
the service life of components. The replacement cost of
the components is extremely high[1]. The cladding of
stainless steel onto carbon steel brings a nice solution to
the problem of the elaboration of a material which
combines high level mechanical properties and good
resistance to corrosion[2]. Literature reveals that many
austenitic stainless steel grades are used for cladding
carbon or low-alloy steels [3-8].
Weld cladding processes have gained popularity
recently in various industries like chemical and fertilizer
plants, nuclear and steam power plants, food processing
and petrochemical industries[9]. Almost all the arc
welding processes have been used for cladding. Most
popular of these are shielded metal arc welding
(SMAW), gas tungsten arc welding (GTAW), gas metal
arc welding (GMAW), submerged arc welding (SAW)
and flux cored arc welding (FCAW) [1, 3, 5, 7, 8, 10-
14]. Use of non-conventional processes such as
explosion welding, strip roll welding, laser welding,
electron beam cladding, solar cladding and microwave
assisted brazing have also been reported in literature for
cladding purpose [2, 15-20].
In semi-automatic and automatic welding and surfacing
processes, engineers often face problems of relating the
process parameters to the weld bead geometry and
dilution of base metal and their optimization. With these
optimized parameters one can achieve sound joints at a
relatively low cost. In the present work, mathematical
models for various bead parameters have been
developed and optimization of ASAW process has been
done to obtain minimal dilution during cladding.
II. BACKGROUND
1.1 Advanced Submerged Arc Welding
Advanced Submerged Arc Welding (ASAW) process
was developed in Welding Research Laboratory of
Indian Institute of Technology Delhi (Sunil Pandey,
2004, Patent application number: 2533 / DEL / 2008
Dated: November 07, 2008). Its working differs from
conventional submerged arc welding (SAW) in that the
electrode wire is preheated before it is fed to the molten
pool on the work piece by using an auxiliary power
source[21]. The welding setup has two contact tubes
instead of one used in conventional submerged arc
welding process. The schematic diagram of the ASAW
setup is shown in Figure 1. Two contact tubes are
separated with a dielectric gap between them. The main
power source is used for creating arc between the
electrode and the base metal as in the normal welding
operation and the other is used for preheating of the
electrode wire. Figure 2 illustrates the actual ASAW
setup photograph.

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43

Figure 1: Schematic diagram for Advance Submerged
Arc Welding (ASAW) setup
In the ASAW process, part of the energy required to
melt the wire is extracted through preheating (I
2
R
heating or simply resistance heating) by passing current
across certain length of the welding wire through
auxiliary power source and rest of the energy for melting
is provided by main welding current. A significant
decrease in welding current due to preheating of wire is
observed which in turn reduces arc force. This results in
lowering down penetration depth and consequently
reduced weld dilution [22].
Process parameters are important as careful selection of
these is responsible for producing quality weld jointsor
weld overlay cladding. Various parameters associated
with the ASAW are similar to SAW e.g., wire feed rate,
welding voltage, travel speed, electrode stick-out,
electrode polarity and flux composition except preheat
current which is a special feature of this process.
1.2 Bead profile and dilution
Figure 3 shows the details of weld bead geometry. The
bead width W, height of reinforcement H and depth
of penetration P primarily dictate the shape of
deposited bead. Height of reinforcement H basically
represents the protruded portion of the bead which is
built up as a result of filler meal deposition on the base
metal surface and is measured as the distance of highest
point from the base metal surface. Penetration P is the
depth of the base metal melted down due to arc heat and
is measured downward from base metal surface upto
lowest point where melting has taken place.
Performance of a weld clad or joint depends on the
extent of percentage dilution, which indicates the extent
of mixing of parent metal with the filler one and equals
the amount of base metal melted divided by the sum of
base metal melted (AP) and filler metal added (AR), the
quotient of which is multiplied by100 [23].
% Dilution = [AP / (AR + AP)] 100 (1)
A successful weld cladding requires careful and
optimizedcontrol of the process parameters to secure
low dilution and a crack-free overlay. This needs a
thorough understanding of the process characteristics
affecting the technological and metallurgical
characteristics of the overlays[24].

Figure 2: Schematic weld bead profile
III. EXPERIMENTATION
1.3 Experimental setup
The experiments were carried out using Advanced
Submerged Arc Welding process. A direct current
constant voltage power source and mechanized
submerged arc welding equipment with a current
capacity of 600 amperes at 60% duty cycle was used for
the experimentation. Welding head was modified by
employing two contact tubes with a dielectric gap in
between. First contact tube was connected to a separate
constant current auxiliary power source which was used
for supplying preheat current through the electrode.
Welding current was supplied through second contact
tube across the welding circuit.
1.4 Material selection and identification of process
parameters limits
A single bead on plate technique was used to deposit
stainless steel beads on 300mm x 75mm x 12 mm mild
steel plates. SFA/AWS 5.9 class ER308L stainless steel
single bare wire electrode of 3.15 mm diameter was
used as a clad metal. A compatible agglomerated flux
(AWS SFA A-5.23) was used to shield the weld metal
from atmospheric contamination.
Four major independent parameters i.e. wire feed rate
F, travel speed S, open circuit voltage V
o
, nozzle to
plate distance N as suggested by many researchers for
submerged arc welding were chosen for the present
work. An additional fifth parameter i.e. preheating
current I
P
, the characteristic ASAW process parameter,
along with the above four was also selected for the
study.
The working limits of selected parameters were finalized
on the basis of extensive trial runs. Minimum and
maximum levels of each parameter as shown in Table 1,
were decided by inspecting the resulting bead on plate
carefully during trial experiments. Only those parameter
limits were selected, which produced beads free of any
visible welding defect like surface porosity, undercut,
overlap, excessive convexity, cracks and showed smooth
and uniform appearance throughout the length[25].
1.5 Recording of responses
Welding current and welding voltage were recorded
during each experimental run. Plates with deposited
Auxiliary Power
Source for Preheating
Constant Voltage
Welding Power
source
Filler Wire
Spool
Dielectric
Gap
Flux
Hopper
Flux
Covering Arc
Wire Electrode
Wire Feed
Rollers
Weld Bead
Workpiece
connection
Base
Metal/Workpiece
Workpiece Support
Direction of
welding
Copper
contact
tube
Electrode
connection
Bead Width
(W)
Reinforcement
(H)
Penetration (P)
HAZ Width
Area of Reinforcement
(AR)
Base Metal
HAZ Area
Area of Penetration
(AP)
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44
beads were allowed to cool in still air upto room
temperature. Initial and final bead portions of 50 mm
length werediscarded in order to avoid arc start and stop
defects. Three specimens of about15 mm thickness (one
at centre and two at both the ends) were then
transversely cut using abrasive wheel cutter. The
specimens so obtained were then moulded with Bakelite
and polished thereafter, using fine grade emery papers.
Polished specimens were then chemically etched with
2% Nital solution in order to reveal different zones of
deposited bead[26]. Various bead zones like
reinforcement area, penetration area, were measured
after scanning the specimen and using digital measuring
tools.
1.6 Development of mathematical model
1.6.1 Response surface methodology
Response surface methodology (RSM) is useful for
modelling and analysis of problems with several
variables and where objective is to optimize the multiple
responses. Response function Y can be expressed in
terms of process parameters as Y = f (F, S, V
o
, N, I
P
)
The model includes the main effects and interaction
effects of all the factors. Second order polynomial,
which was adopted for the present study, is represented
by following general expression.
y =
0
+
i
x
i
+
ii
x
i
2
+
ij
x
i
x
j
+
i<j
k
i=1
k
i=1
(2)
Where
0
,
ii
and
ij
are the constants and x
i
, is the
process variable and is the error term of the model
[27].
1.6.2 Formation of Design matrix and testing the
adequacy of developed models
The five levels of welding parameters based on half
fraction rotatable central composite design (CCD) for
RSM were selected and coded according to Table 1 and
then design matrix consisting 30 test conditions was
created using Design Expert 8 statistical software. This
design matrix is illustrated by Table 2. Adequacy of the
model was confirmed by using Analysis of Variance
(ANOVA) technique. The results of ANOVA for
responses are shown in Table 3. This table shows details
of sum of squares (SS), degrees of freedom (DF), mean
square (MS), F- Ratio and Probability of larger F- value
or simply P-value [28]. Figure 3 represents the normal
probability plot vs. Studentized residuals plots for all the
observations on bead width, reinforcement, penetration
and % dilution. It is concluded that the assumption of a
normal distribution is reasonable since all the plotted
points fall on a straight line.

Figure 3: Normal probability vs. Studentized residuals
for various responses
1.6.3 Checking the significance of coefficients
The statistical significance of the coefficients was tested
by applying the t test. Coefficients having t values
less than or equal to the standard tabulated t value at
95% confidence level, are considered non-significant
and can be ignored along with the responses with which
they are associated and affecting minutely the accuracy
of the proposed model [29, 30]. Table 4contains F-
values and P-values for individual parameters in the
respective models for bead width, reinforcement,
penetration and percentage dilution. Factors with the P-
values less than 0.05 are significant and are included in
the final model.
Internally Studentized Residuals
N
o
r
m
a
l

%

P
r
o
b
a
b
i
l
i
t
y
Normal Plot of Residuals
-3.00 -2.00 -1.00 0.00 1.00 2.00
1
5
10
20
30
50
70
80
90
95
99
Normal plot of Residuals for bead width (W)
(a)
N
o
r
m
a
l

%

P
r
o
b
a
b
i
l
i
t
y
-2.00 -1.00 0.00 1.00 2.00
1
5
10
20
30
50
70
80
90
95
99
Normal plot of Residuals for reinforcement (H)
(b)
N
o
r
m
a
l

%

P
r
o
b
a
b
i
l
i
t
y
-2.00 -1.00 0.00 1.00 2.00 3.00
1
5
10
20
30
50
70
80
90
95
99
Normal plot of Residuals for penetration(P)
(c)
N
o
r
m
a
l

%

P
r
o
b
a
b
i
l
i
t
y
-2.00 -1.00 0.00 1.00 2.00
1
5
10
20
30
50
70
80
90
95
99
Normal plot of Residuals for dilution(%D)
(d)
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45
1.6.4 Optimization using desirability function
In 1980, Derringer and Suich[31] suggested a method
for optimization of multiple response problems in
industries. According to them, an estimated response y
i

is transformed into a scale free individual desirability
function ( d
i
) that varies between 0 & 1. Optimal
parameter conditions for multiple responses are decided
by finding overall desirability value , which is
represented as geometric mean of individual desirability
function (d
i
) as given in following equation 3.
= d
1
. d
2
. d
3
d
p
1 p
(3)
where, pis the number of responses to be considered for
optimization.
IV. RESULTS AND ANALYSIS
1.7 Final mathematical models
Following equations have been finalized keeping
significant parameter coefficients and omitting
insignificant parameter coefficients. Equations 4 to 7
represent regressions in terms of coded factors, while
equations 8 to 11 show correlation in terms of actual
factors[32].
1.7.1 Final Equation in Terms of Coded Factors:
lnW = 2.47 0.12 S + 0.14 V
o
...(4)
H
1.43
= 0.13 0.021 F + 0.023 S +
0.019 V
o
...(5)
P = 3.34 + 0.41 F 0.23 S 0.25 I
P
...(6)
% D = 38.13 + 2.52 S + 2.89 Vo 1.79
I
P
...(7)
1.7.2 Final Equation in Terms of Actual Factors:
ln(W) = 1.19726 0.080839 S + 0.047684
V
o
...(8)
(H)
1.43
= 0.039 5.146 10 03 F +
0.0155 S + 6.31 10 03 V
o
...(9)
P = 1.86 + 0.102 F 0.155 S 5.992
10 03 I
P
...(10)
% D = 2.166 + 1.681 S + 0.962 Vo
0.043 I
P
..(11)
1.8 Effect of process parameters on Bead width
Equation 4 suggests that the bead width W depends
directly on travel speed and open circuit voltage. As the
travel speed is increased the bead width decreases
because the melting rate per unit length of weld is
decreased. These variations of bead width with the
parameters are depicted in figure 4a.An increase in open
circuit voltage leads to an increase in bead width which
can easily be explained by corresponding increase in arc
length. There are no interactions found between any of
the process parameters. Figure 5 illustrate the variation
of bead width with open circuit voltage at various levels
of travel speed.
1.9 Effects of process parameters on
Reinforcement Height
Reinforcement height H is affected by many
parameters. Direct effect of parameters can be clearly
seen. Equation 5 shows that wire feed rate F, affect the
value of H in a positive manner i.e. increasing wire
feed rate leads to increased H. Travel speed S and
open circuit voltage V
o
affect reinforcement height in a
negative pattern. Rate of decrease in reinforcement
height with respect to travel speed is slightly more than
that with open circuit voltage as shown in figure 4b.
This can be explained as follows; (a) higher the wire
feed rate more will be the amount of molten filler metal,
so for the same bead width, reinforcement height should
increase to accommodate the increased amount of filler
metal (b) for increased travel speeds, less filler metal per
unit length is available which results in smaller
reinforcement (c) as explained earlier larger open circuit
voltage means long and wider arc that produces
comparatively a flatter bead and hence lower
reinforcement height is obtained. Figure 6 shows the
variation of reinforcement with wire feed rate at various
levels of travel speed and open circuit voltage.
1.10 Effects of process parameters on penetration
Correlation shown by Equation 6 in terms of coded
factors illustrate the main effects of wire feed rate F,
travel speed S and preheat current I
P
on penetration
P. The value of penetration increases with wire feed
rate and decreases with corresponding increase in travel
speed and preheat current as indicated in figure 4c.
Travel speed and preheat current produce almost same
penetration decrease rate. Since more wire feed rate is
associated with higher current values, resulting arc force
thus obtained is more and has the ability to penetrate
deep into base metal. At low travel speeds, heat input
per unit length of the base metal is less and the result is
lesser penetration. Preheat current in ASAW process is
used for maintaining the melting rate of the wire by a
simultaneous decrease in welding current, so a lesser arc
force is available at the base metal surface which
prohibits penetrating intensity. It is again concluded that
there are no interactions found between any of the
parameters. Figure 7 indicates, more clearly, the
variation of penetration with wire feed rate at various
levels of travel.
1.11 Effects of process parameters on % dilution
Correlation given by Equation 7 illustrate that the
significant parameters that affect the percentage dilution
in ASAW process are travel speed S, open circuit
voltage V
o
and preheat current I
P
. It is understood
that the increase in travel speed and open circuit voltage
increases %dilution but when preheating current is
enhanced the latter is decreased. This variation is clearly
illustrated in figure 4d.
This shows the importance of preheating welding
electrode wire. Increase in dilution with increasing
travel speed can be explained as, with an increase in the
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46
travel speed, amount of molten metal between the arc
and the fresh base metal is decreased and arc is able to
penetrate deeply into the base metal. With an increase in
open circuit voltage upto certain limit the arc becomes
hotter and gains the ability to penetrate deeper into base
metal which in turn, helps in diluting the deposited
metal more.
Increased preheat current lowers down the welding
current which affect the arc force adversely and hence
the penetration. On the other side, there is a little effect
on the filler metal deposition rate as the melting rate is
made up by heat produced due to preheating current
through the electrode. It results in rapid decrease of
penetration area in comparison to reinforcement area
and therefore, the dilution is decreased. Variation of
percentage dilution with respect to various parameters in
the form of response surface plots is shown in Figures8-
10.

Figure 4: Direct effects of parameters on responses

Figure 5: Variation of bead width with open circuit
voltage at various levels of welding speed

Figure 6: Variation of reinforcement with wire feed rate
at various levels of welding speed and open circuit
voltage

8
10
12
14
16
18
-2 -1 0 1 2
B
e
a
d

w
i
d
t
h
(
W
)
,

m
m
Factors at coded value
S
Vo
(a)
3
4
5
6
-2 -1 0 1 2
R
e
i
n
f
o
r
c
e
m
e
n
t
(
H
)
,

m
m
F
S
Vo
(b)
2.5
3.5
4.5
-2 -1 0 1 2
P
e
n
e
t
r
a
t
i
o
n

(
P
)
,

m
m
F
S
Ip
(c)
30
35
40
45
-2 -1 0 1 2
%
D
i
l
u
t
i
o
n

(
%
D
)
S
Vo
Ip
(d)
5
10
15
20
25
30 33 36 39 42
B
e
a
d

w
i
d
t
h
(
W
)
,

m
m
Open Circuit Voltage, V
S=2.5
S=4
S=5.5
S=7
S=8.5
F= 28
N= 24
I
P
=84
2.5
5
7.5
10
20 24 28 32 36
R
e
i
n
f
o
r
c
m
e
n
t
(
H
)
,

m
m
Wire Feed rate(WF), mm/s
S=2.5
S=4
S=5.5
S=7
S=8.5
V
o
= 36 V
N= 24
I
P
= 84
(a)
2.5
5
7.5
10
20 24 28 32 36
R
e
i
n
f
o
r
c
e
m
e
n
t
(
H
)
,

m
m
Vo=30
Vo=33
Vo=36
Vo=39
Vo=42
S= 5.5
N= 24
I
P
= 84
(b)
2
3
4
5
20 24 28 32 36
P
e
n
e
t
r
a
t
i
o
n
(
P
)
,

m
m
S=2.5
S=4
S=5.5
S=7
S=8.5
V
o
= 36
N= 24
I
P
= 84
(a)
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47

Figure 7: Variation of penetration with wire feed rate at
various levels of welding speed and preheating current

Figure 8: Response surface plot showing the variation
of percentage dilution with open circuit voltage and
travel speed

Figure 9: Response surface plot showing variation of
percentage dilution with preheating current and travel
speed

Figure 10: Response surface plot showing variation of
percentage dilution with preheat current and open circuit
voltage
1.12 Optimization for dilution
Optimization of the responses was done by using
desirability function as described in section 2.4.4. For
minimal dilution condition to be obtained as needed in
cladding, area of penetration to total bead area ratio
should be minimum. In order to satisfy this condition
bead width and reinforcement height must be maximum
and penetration depth should be minimum during
cladding [7]. Numerical optimization was carried out
using Design Expert 8.0 statistical software. Minimal
value of dilution equal to 30.49% was obtained with a
desirability function of 0.701 under following optimized
process parameter condition as shown in Table 5.
Confirmation run at the suggested optimized ASAW
process parameters were carried out and the resulting
bead on plate geometry and dilution values, as shown in
Figure 11, were found within the 95% confidence limit.

Figure 11: Confirmatory Bead obtained at optimized
parameter conditions

Table 1: Parameters and their values at various levels
Process
parameter
Units Notation Type of
parameter
Parameter levels
-2 -1 0 +1 +2
Open
Circuit
Voltage
Volts Vo Numeric 30 33 36 39 42
Wire Feed
Rate
Numeric 20 24 28 32 36
Welding
Speed
Numeric 2.5 4 5.5 7 8.5
Nozzle to
plate
distance
Numeric 18 21 24 27 30
Preheat
current
Numeric 0 42 84 126 168

2
3
4
5
20 24 28 32 36
P
e
n
e
t
r
a
t
i
o
n
(
P
)
,

m
m
Ip=0 A
Ip=42 A
Ip=84 A
Ip=126 A
Ip=168 A
S= 5.5
N= 24
V
o
= 36
(b)
30
33
36
39
42
2.5
4.0
5.5
7.0
8.5
25
30
35
40
45
50

P
E
R
C
E
N
T
A
G
E

D
I
L
U
T
I
O
N

TRAVEL SPEED, mm/s OPENCIRCUIT VOLTAGE, Volt
0
42
84
126
168
2.5
4.0
5.5
7.0
8.5
25
30
35
40
45
50

P
E
R
C
E
N
T
A
G
E

D
I
L
U
T
I
O
N

TRAVEL SPEED, mm/s PREHEAT CURRENT, Amp
0
42
84
126
168
30
33
36
39
42
30
35
40
45
50

P
E
R
C
E
N
T
A
G
E

D
I
L
U
T
I
O
N

OPEN CIRCUIT VOLTAGE, Volt PREHEAT CURRENT, Amp
_______________________________________________________________________________________________

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48
Table 2: Design Matrix for experimental runs
Run
No.
Coded ASAW process variables Actual response values
F S V
o
N I
P
W (mm) H (mm) P (mm) %D
1 -1 -1 -1 -1 1 11.6 4.6 3.1 34.5
2 1 -1 -1 -1 -1 10.7 6.8 3.9 30.4
3 -1 1 -1 -1 -1 10.2 3.7 2.9 39.6
4 1 1 -1 -1 1 9.2 5.1 3.2 33.8
5 -1 -1 1 -1 -1 14.8 4.2 3.5 41.6
6 1 -1 1 -1 1 17.8 4.5 3.5 36.4
7 -1 1 1 -1 1 10.9 3.1 2.2 36.2
8 1 1 1 -1 -1 12.8 3.9 3.5 42.9
9 -1 -1 -1 1 -1 11.8 4.8 3.6 35.6
10 1 -1 -1 1 1 12.2 5.5 3.9 33.9
11 -1 1 -1 1 1 8.5 3.9 2.5 35.3
12 1 1 -1 1 -1 8.7 4.7 3.3 34.3
13 -1 -1 1 1 1 16.4 4.1 2.8 34.6
14 1 -1 1 1 -1 14.0 5.5 4.3 36.1
15 -1 1 1 1 -1 12.8 3.0 3.7 49.3
16 1 1 1 1 1 12.2 3.8 3.6 44.2
17 -2 0 0 0 0 9.8 3.4 2.3 36.7
18 2 0 0 0 0 12.5 5.3 4.7 41.0
19 0 -2 0 0 0 14.9 7.2 3.7 26.9
20 0 2 0 0 0 9.2 3.7 2.8 40.9
21 0 0 -2 0 0 8.8 5.5 2.9 29.8
22 0 0 2 0 0 15.0 3.5 3.2 42.5
23 0 0 0 -2 0 12.1 4.1 3.9 44.1
24 0 0 0 2 0 11.0 4.1 2.9 34.3
25 0 0 0 0 -2 11.5 4.0 3.9 47.0
26 0 0 0 0 2 11.0 3.7 2.7 35.9
27 0 0 0 0 0 12.9 3.9 3.1 39.3
28 0 0 0 0 0 12.9 4.1 3.6 41.5
29 0 0 0 0 0 10.9 4.4 3.6 39.8
30 0 0 0 0 0 13.1 3.7 3.7 45.4
Table 3: ANOVA test for the fitted models
Source SS DF MS F-Value P-value Significance
(a) Bead Width (W)
Model 0.844 2 0.422 69.039 < 0.0001 significant
Residual 0.165 27 0.006

Lack of Fit 0.143 24 0.006 0.817 0.6772 not significant
Pure Error 0.022 3 0.007

Cor Total 1.009 29

Std. Dev.=0.078, R-Squared= 0.836, Adj R-Squared= 0.824
(b) Reinforcement (H)
Residual 0.005 26 0.000

Pure Error 0.001 3 0.000

Cor Total 0.036 29

Std. Dev. = 0.013, R-Squared = 0.875, Adj R-Squared = 0.861
Table 3 continued.
Source SS DF MS F-Value P-value Significance
(c) Penetration (P)
Residual 2.552 26 0.098

Pure Error 0.222 3 0.074

Cor Total 9.334 29

_______________________________________________________________________________________________

_______________________________________________________________________________________________
49
(d) %Dilution (%D)
Model 429.462 3 143.154 10.197 0.0001 significant
Residual 365.009 26 14.039

Pure Error 22.666 3 7.555

Cor Total 794.471 29


Table 2: Testing of significance for each parameter in developed models
Factors DF
Bead width (W) Reinforcement (H) Penetration (P) Dilution (%D)
F- Value P-Value F- Value P-Value F- Value P-Value F- Value P-Value
F 1 1.561 0.2235 56.524 < 0.0001 38.179 < 0.0001 0.105 0.7488
S 1 55.964 < 0.0001 72.211 < 0.0001 12.573 0.0016 10.228 0.0039
V
o
1 77.890 < 0.0001 47.806 < 0.0001 0.611 0.4419 13.405 0.0012
N 1 0.605 0.4441 0.001 0.9738 0.001 0.9700 0.366 0.5510
I
P
1 0.007 0.9335 1.233 0.2779 14.662 0.0008 5.158 0.0324

Table 3: Optimized ASAW parameter condition for minimal dilution value
F S V
O
N I
P
W H P %D Desirability
29.3 4 33 23 126 11.56 5.82 3.46 30.94 0.701

V. CONCLUSION
Dilution has a great impact on the chemical composition
of the SS clad layer as a result of intens mixing with the
substrate, mild steel in this case. Prediction of %dilution
is important in the sense that several mechanical,
metallurgical, chemical properties are greatly influenced
by the extent of dilution. Least amount of dilution is the
need for a cladding opreation. Advanced submerged arc
welding (ASAW) thus enhances the versatility of
conventioal submerged arc welding to make it more
useful for cladding operation as dilution levels can be
reduced significantly by introducing preheating current
through the electrode wire. Findings of present work
may be concluded as follows;
1. Bead width is influence by travel speed and open
circuit voltage
2. Reinforcement is a function of wire feed rate,
travel speed and open circuit voltage
3. Penetration is greatly affected by wire feed rate and
preheating current.
4. Percentage dilution depends on travel speed, open
circuit voltage and preheating current.
5. Advanced submerged arc welding economically
provides an efficient alternative for quality
surfacing /cladding operations as dilution is
considerably reduced.
6. At very low open circuit voltage and travel speeds
submerged arc welding process cannot be operated
to give quality welds. In this situation, advanced
submerged arc welding (ASAW) provides further
significant reduction in dilution maintaining the
other parameters within their range and still
maintaining the quality of welding/surfacing
operation.
7. An optimized value of dilution equal to 30.94%
was obtained as a result of optimization using
desirability function which was later confirmed by
depositing confirmation run.
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