Effect of wire feed speed and arc length on weld bead geometry in synergistic controlled pulsed MIG/MAG welding

Ekrem Arslan; Erdal Karadeniz; Erol Feyzullahoğlu

doi:10.1515/mt-2024-0194

Article

Effect of wire feed speed and arc length on weld bead geometry in synergistic controlled pulsed MIG/MAG welding

Ekrem Arslan
Mr.

Ekrem Arslan graduated from Kocaeli University in 2013 with a degree in Mechanical Engineering. He received his MSc degree from the Department of Mechanical Engineering at Sakarya University. Since 2015, he has been working as a R&D Engineer at various companies and currently holds the position of R&D Engineer at Siro Energy. His research interests include encompass mechanical design, electric motors, electric vehicle batteries, welding, and tribology.
, Erdal Karadeniz
Dr.

Erdal Karadeniz is an Assistant Professor at the University of Sakarya, Türkiye. He received his Ph.D in Metallurgy Engineering from the University of Istanbul Technical in 1997. His research interests include heat treatment, manufacturing technologies, and additive manufacturing.
and Erol Feyzullahoğlu
Prof. Dr.

Erol Feyzullahoğlu, is presently working in the Department of Mechanical Engineering, Kocaeli University, Turkey. He obtained his undergraduate and graduate degrees in Mechanical Engineering Department of Yıldız Technical University and his doctoral degree in Mechanical Engineering Department of Kocaeli University. He has lectured in different engineering disciplines including Mechanical Engineering. His research interests include the areas of tribology, wear, machine elements, and transport technique.

Published/Copyright: December 6, 2024

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From the journal Materials Testing Volume 67 Issue 1

Abstract

Arc welding is one of the most commonly applied methods in the welded manufacturing industry. The pulse MIG/MAG welding method (GMAW-P) was developed to prevent problems that may occur in the weld bead due to high heat input to the base metal during the feeding of the weld metal in MIG/MAG welding applications. The synergistic controlled welding machines have been developed that facilitate the selection of welding parameters and provide simultaneous feeding of pulsed welding wire by adjusting the variables to the most appropriate values relative to each other. Weld bead geometry is greatly influenced by welding process parameter, i.e., welding speed, welding current, shielding gas flow rate, voltage, arc travel speed, type of shielding gas, etc. In this study, steel welding samples in T-joint shape were produced with synergistic controlled GMAW-P. The effect of welding parameters on weld bead geometry was investigated. As a result of this study, it was determined that increases in weld wire feed speed, arc voltage, and welding current increased weld depths of penetration and weld bead thickness.

Keywords: synergistic control; GMAW-P; wire feed speed; arc length; weld bead geometry

Corresponding author: Erol Feyzullahoğlu, Faculty of Engineering, Mechanical Engineering Department, Kocaeli University, İzmit, Kocaeli, 41380, Türkiye, E-mail: feyzullahoglu@yahoo.com

About the authors

Ekrem Arslan

Mr.

Ekrem Arslan graduated from Kocaeli University in 2013 with a degree in Mechanical Engineering. He received his MSc degree from the Department of Mechanical Engineering at Sakarya University. Since 2015, he has been working as a R&D Engineer at various companies and currently holds the position of R&D Engineer at Siro Energy. His research interests include encompass mechanical design, electric motors, electric vehicle batteries, welding, and tribology.

Erdal Karadeniz

Dr.

Erdal Karadeniz is an Assistant Professor at the University of Sakarya, Türkiye. He received his Ph.D in Metallurgy Engineering from the University of Istanbul Technical in 1997. His research interests include heat treatment, manufacturing technologies, and additive manufacturing.

Erol Feyzullahoğlu

Prof. Dr.

Erol Feyzullahoğlu, is presently working in the Department of Mechanical Engineering, Kocaeli University, Turkey. He obtained his undergraduate and graduate degrees in Mechanical Engineering Department of Yıldız Technical University and his doctoral degree in Mechanical Engineering Department of Kocaeli University. He has lectured in different engineering disciplines including Mechanical Engineering. His research interests include the areas of tribology, wear, machine elements, and transport technique.

Acknowledgment

The authors express their gratitude to OM Engineering-Türkiye for their generous support in welding samples.

Research ethics: Not applicable.
Informed consent: Not applicable.
Author contributions: The authors have accepted responsibility for the entire content of this manuscript and approved its submission. The details are presented at the end of the article.
Use of Large Language Models, AI and Machine Learning Tools: None declared.
Conflict of interests: The authors state no conflict of interest.
Research funding: None declared.
Data availability: Not applicable.

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Published Online: 2024-12-06

Published in Print: 2025-01-29

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Articles in the same Issue

https://doi.org/10.1515/mt-2024-0194

Keywords for this article

synergistic control; GMAW-P; wire feed speed; arc length; weld bead geometry