PRODUCTION & MANUFACTURING | RESEARCH ARTICLE
Influence of heat input on weld bead geometry
using duplex stainless steel wire electrode on low
alloy steel specimens
Ajit Mondal, Manas Kumar Saha, Ritesh Hazra and Santanu Das
Cogent Engineering (2016), 3: 1143598
Page 1 of 14
Mondal et al., Cogent Engineering (2016), 3: 1143598
http://dx.doi.org/10.1080/23311916.2016.1143598
PRODUCTION & MANUFACTURING | RESEARCH ARTICLE
Influence of heat input on weld bead geometry
using duplex stainless steel wire electrode on low
alloy steel specimens
Received: 24 October 2015
Accepted: 09 January 2016
First Published: 28 January 2016
*Corresponding author: Santanu Das,
Department of Mechanical Engineering,
Kalyani Government Engineering
College, Nadia, Kalyani, 741235, West
Bengal, India
Email: sdas.me@gmail.com
Reviewing editor:
Zude Zhou, Wuhan University of
Technology, China
Additional information is available at
the end of the article
Ajit Mondal
Ajit Mondal1, Manas Kumar Saha1, Ritesh Hazra1 and Santanu Das1*
Abstract: Gas metal arc welding cladding becomes a popular surfacing technique in
many modern industries as it enhances effectively corrosion resistance property and
wear resistance property of structural members. Quality of weld cladding may be
enhanced by controlling process parameters. If bead formation is found acceptable,
cladding is also expected to be good. Weld bead characteristics are often assessed
by bead geometry, and it is mainly influenced by heat input. In this paper, duplex
stainless steel E2209 T01 is deposited on E250 low alloy steel specimens with
100% CO2 gas as shielding medium with different heats. Weld bead width, height of
reinforcement and depth of penetration are measured. Regression analysis is done
on the basis of experimental data. Results reveal that within the range of bead-onplate welding experiments done, parameters of welding geometry are on the whole
linearly related with heat input. A condition corresponding to 0.744 kJ/mm heat
input is recommended to be used for weld cladding in practice.
ABOUT THE AUTHORS
PUBLIC INTEREST STATEMENT
Ajit Mondal is an Assistant Professor of Mechanical
Engineering in Camellia Institute of Technology,
Madhyamgram, Kolkata and a Visiting Faculty in
Kalyani Government Engineering College, Kalyani.
He is currently working in GMAW based cladding
process.
Manas Kumar Saha is a Lecturer in Mechanical
Engineering at Engineering Institute for Junior
Executives, Howrah, India. He is doing research
work on weld cladding at Kalyani Government
Engineering College, Kalyani. He served in
Hindustan Motors Ltd., Kolkata, and Nazrul
Centenary Polytechnic, Burdwan, India.
Ritesh Hazra did B.Tech and M.Tech from Kalyani
Govt. Engineering College, Kalyani, India. He
is currently working on GMAW based cladding
process.
Dr. Santanu Das is Professor and Head of
Mechanical Engineering Department, Kalyani
Government Engineering College, Kalyani. He
did his Bachelors and Masters from Jadavpur
University, Kolkata and obtained Ph.D. from
Indian Institute of Technology, Kharagpur. His
area of research includes machining, grinding,
tool condition monitoring, welding, production
management, etc.
This article deals with gas metal arc welding
performance with regard to depositing duplex
stainless steel on a low alloy steel base plate. For
any arc welding process, heat input to the process
plays an important role to achieve good weld
material deposition. In this work, weld beads are
formed on base plate with varying heat input.
Investigation is made to find out the condition
to have high weld bead reinforcement above the
base plate with large bead width maintaining
small depth of penetration. Large reinforcement
and bead width cause thick and wide covering of
stainless steel onto the base plate. Process parameters are, therefore, needed to choose in such a
way that this kind of corrosion-resistant stainless
steel would be used to cover a less costly, corrosion
prone steel to render prolonged service life of an
equipment or structure subjected to highly corrosive atmosphere.
© 2016 The Author(s). This open access article is distributed under a Creative Commons Attribution
(CC-BY) 4.0 license.
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Subjects: Manufacturing & Processing; Manufacturing Engineering; Manufacturing Technology
Keywords: GMAW; heat input; weld bead; bead geometry; regression analysis
1. Introduction
In recent times, costly materials having good surface-dependent properties like corrosion resistance
is overlaid on relatively cheap corrosion-prone material to increase its performance in severe service
conditions for relatively long period. Cladding is one such process called surfacing technique where
a relatively thick coating up to several milimetres is applied (Nadkarni, 1988; Parmar, 2010).
Different types of surfacing techniques are used by means of depositing different materials and,
metallic materials, in particular. The methods used are coating, plating, buttering, cladding, metal
spraying, etc.
Cladding is a surfacing technique that involves improvement of surface strength of mother metal
considerably to increase service life of the parent material without changing the microstructure of
the base material (Rao, Reddy, & Nagarjuna, 2011). Cladding creates a new surface layer with different compositions which, in general, is harder than the base material. Comparing with other techniques used for surface treatment by means of material deposition, cladding has some distinct
advantages, such as it provides high hardness, corrosion and/or erosion resistance, good bonding
and favourable microstructure (Funderburk, 1999).
Nowadays, weld cladding processes are used in numerous industries and plants, such as chemical
and fertilizer plant, aviation industry, mining industry, agriculture, sea water application (Wilson,
Kelly, & Kiser, 1987), power generation, food processing and photochemical industries as a cost-effective engineering solution against corrosion attack (Kang & Lee, 2014).
Among various welding processes employed for cladding, gas metal arc welding (GMAW) is widely
utilized in industry due to some advantages (Lucas, 1994). GMAW cladding has high reliability, all
position capability, ease of use, low cost, high productivity, suitability for both ferrous and nonferrous metals and alloys, high deposition rate, absence of flux, cleanliness and ease of mechanization
(Kannan & Murugan, 2005). One point to note is that any good-quality weld cladding needs minimum dilution (Shahi & Pandey, 2008). Mechanical strength of GMAW clad metal is influenced not
only by the composition of the metal but also by the clad bead shape and its geometry. The acceptable clad bead geometry depends (Jha, Bhardwaj, Bhagatand, & Sharma, 2014; Khara, Mondal,
Sarkar, & Das, 2011; Murugan & Parmar, 1994; Verma et al., 2013) on arc voltage, welding current,
gas flow rate (Saha, Das, Bandyopadhyay, & Bandyopadhyay, 2012), wire feed rate, welding speed,
torch angle, tip-to-nozzle distance, etc. Hence, the relationship between input process parameters
and bead parameters is necessary to explore (Kumar, Singh, & Yusufzai, 2012).
In some recent investigations, properties of duplex stainless steel cladding on lower grade steel by
GMAW were investigated using CO2 as the shielding gas (Chakrabarti, Das, Das, & Pal, 2013; Kumar
et al., 2012; Sreeraj, Kannan, & Maji, 2013a; Verma et al., 2012). In particular, the influence of heat
input and shielding gas composition in GMAW on weld deposit geometry were studied (Palani &
Murugan, 2006; Senthilkumar & Kannan, 2013; Shahi & Panday, 2008; Sreeraj & Kannan, 2012).
Various mathematical models have been successfully developed among heat input and weld geometry parameters in specific welding atmosphere (Kannan & Yoganandh, 2010; Palani & Murugan,
2005; Rajkumar & Murugan, 2014a, 2014b; Sreeraj, Kannan, & Maji, 2013b, 2013c). At the end, the
claddings should offer enough erosion and/or corrosion resistance.
In the present work, GMAW experiments are conducted to find out the influence of process parameters and corresponding heat inputs on weld bead geometry under 100% CO2 gas shield. Duplex
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Table 1. Composition of base plate (E250)
%C
%Si
%Mn
%P
%S
%Ni
%Mo
%Nb
%Pb
%Sn
%As
%Fe
0.199
0.14
0.498
0.06
0.03
0.025
0.038
0.01
0.01
0.014
0.066
Rest
Table 2. Composition of duplex stainless steel filler wire (E2209 T01)
%C
%Si
%Mn
%P
%S
%Cr
%Mo
%Ni
%N
%Fe
0.02
0.76
1.01
0.018
0.009
22.52
2.91
9.09
0.125
Rest
stainless steel wire electrode is used to make bead-on-plate made of low alloy steel. Regression
analysis is done for evaluating relations among different parameters of weld bead geometry and
heat input.
2. Experimental procedure
Bead-on-plate experiments are performed using ESAB, India made Auto K400 GMAW machine having voltage and current capacity of 0–75 V and 0–400 A, respectively. 100% CO2 gas with a constant
gas flow rate of 16 l/min is used as shielding gas throughout the experiment. E250 low alloy steel
base plates are of size 55 mm × 45 mm × 25 mm. These thick specimens are used to avoid any distortion in it. Composition of E250 steel base plate and E2209 T01 duplex stainless steel wire electrode
are given in Tables 1 and 2. Carbon Equivalent, Ceqv of the base metal is found to be 0.29, and that of
the duplex stainless steel filler wire is 5.88 signifying this in the pro-eutectic zone.
Process parameters chosen for bead-on-plate experiments performed and corresponding heat
input values are detailed in Table 3. Heat input serves a significant role in welding. Proper heat input
provides greater penetration, favourable fusion and sufficient bonding in cladding. Cooling rate,
weld size and material properties may all be influenced by the heat input (Chakrabarti et al., 2013;
Funderburk, 1999; Nadkarni, 1988; Verma et al., 2013) which is calculated using Equation (1).
Q=
(60 × V × I)
×𝜂
(1000S)
(1)
where Q is the heat input (kJ/mm), V is the welding voltage (V), I is the welding current (A), and S is
the welding torch travel speed (mm/min), and η is the efficiency for the welding process (in this work
on GMAW, it is taken to be 0.8 (Nadkarni, 1988)).
Photographs of bead-on-plate samples obtained through second replication of experiments are
shown in Figure 1. Top views of the weld beads on plate are depicted in Figure 1(a), while Figure 1(b)
indicates front views of these nine weld beads. Weld bead geometry, such as reinforcement (R),
depth of penetration (P) and weld bead width (W) are measured under tool makers’ microscope after
polishing of cut crosswise samples. A typical weld bead geometry is schematically shown in Figure
2. Reinforcement form factor (RFF) and penetration shape factor (PSF) are evaluated next from the
bead geometry parameters following Equations (2) and (3).
RFF =
W
R
(2)
PSF =
W
P
(3)
where W is the weld bead width (mm), R is the height of reinforcement (mm), and P is the depth of
penetration (mm).
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Table 3. Parameters of bead-on-plate experiment
Sample no.
Voltage (V)
Current (A)
Travel speed (mm/min)
Heat input (kJ/mm)
S1
22.5
120
390
0.332
S2
25
160
390
0.358
S3
24
160
390
0.472
S4
24
140
450
0.492
S5
26
180
450
0.499
S6
28
190
450
0.567
S7
29
200
480
0.580
S8
30
220
480
0.660
S9
31
240
480
0.744
3. Results and discussion
3.1. Visual inspection
Table 4 shows results of visual inspection of bead-on-plate experiments. No blow hole is obtained in
the present experiment. Deposition of weld pool is found to be continuous in the cases. Occasional
spatter is observed in some of experiments. On the whole, good consistency within the two replicated experiments is apparent.
Small spatter seen in experiments No. 7 and 9 may be due to high weld current used under CO2 gas
shield. However, no spatter is detected in experiment No. 8 with the same high weld current in both
the replications that could not be explained.
3.2. Observation on weld bead geometry
Figure 1 depicts views of weld beads of experiments of second replication. Weld bead geometry
parameters (as shown in Figure 2), such as height of reinforcement, width of weld bead and depth
of penetration are shown in Table 5 that are also clearly visible in the front view of the weld bead
section (Figure 1(b)). The RFF and PSF are evaluated following Equations (1) and (2). Tables 5 and 6
show evaluated RFF and PSF values of bead-on-plate experiments for the two replicated sets of
experiments.
Graphical representations of different weld bead geometry parameters obtained from first and
second replications of bead-on-plate experiments as detailed in Tables 5 and 6 are shown in Figure
3 through Figure 7.
The effect of heat input on reinforcement as observed in bead-on-plate experiments is shown in
Figure 3. The plot is constructed with the average value of reinforcement as obtained from the two
replications of experiments. Dispersion of reinforcement indicating the higher and smaller values is
also indicated at each point of experimental observation. The figure shows that on the whole, reinforcement increases with increasing heat input. Less dispersion as seen in Figure 3 indicates consistency in replicated experiments. Maximum value of reinforcement height is obtained at a heat input
of 0.66 kJ/mm. However, at a higher heat input of 0.744 kJ/mm, reinforcement shows a slight decrease. Small spatter observed at this condition may have resulted in this. Increase in heat input
Figure 1. Photographs of beadon-plate samples obtained
through second replication of
experiments ((a) top view of
the weld beads on plate and (b)
front view of weld beads).
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Figure 2. A typical weld bead
geometry schematic.
Table 4. Visual inspection of bead-on-plate experiments
Sample no.
Voltage, V
(V)
Current, I
(A)
Travel
speed, S
(mm/min)
Heat input
(kJ/mm)
Blow hole
in both
replication
Continuity
in
deposition
in both
replication
1st
replication
2nd
replication
22.5
120
390
0.332
Nil
Continuous
Nil
Nil
1
Spatter
2
25
160
390
0.358
Nil
Continuous
Nil
Nil
3
24
160
390
0.472
Nil
Continuous
Very few
Nil
4
24
140
450
0.492
Nil
Continuous
Nil
Nil
5
26
180
450
0.499
Nil
Continuous
Nil
Nil
6
28
190
450
0.567
Nil
Continuous
Nil
Nil
Very few
7
29
200
480
0.580
Nil
Continuous
Very few
8
30
220
480
0.660
Nil
Continuous
Nil
Nil
9
31
240
480
0.744
Nil
Continuous
Very few
Very few
corresponding to hike in weld current or voltage, or reduction in weld torch speed, causes higher
heat energy input to the weld zone causing higher volume of melting of electrode material and enlarged volume of weld zone. It is also known that weld current imparts greater influence on heat
input than voltage. Travel speed influences welding time and heat accumulation occurs corresponding to heat conduction property of the work material. Naturally, larger reinforcement height, R with
higher heat input is expected in general in these tests on bead-on-plate welding.
Table 5. RFF and PSF of bead-on-plate experiments of first replication
Sample
no.
1
Voltage, V
(V)
Current,
I (A)
Travel
speed, S
(mm/min)
Heat
input (kJ/
mm)
Height of
reinforce
ment, R
(mm)
Weld
bead
width, W
(mm)
Depth of
penetra
tion, P
(mm)
RFF = (W/R)
PSF = (W/P)
22.5
120
390
0.332
2.445
7.775
1.355
3.179
5.738
2
24
140
450
0.358
2.43
8.775
1.485
3.611
5.909
3
24
160
390
0.472
2.665
9.543
1.555
3.580
6.136
4
25
160
390
0.492
2.785
9.785
1.6
3.513
6.115
5
26
180
450
0.499
3
10.6
1.78
3.533
5.955
5.937
6
28
190
450
0.567
3.1
10.985
1.85
3.543
7
29
200
480
0.580
3.15
12
1.95
3.809
6.153
8
30
220
480
0.660
3.295
13.385
1.899
4.062
7.048
9
31
240
480
0.744
3.215
14.33
1.985
4.457
7.219
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Table 6. RFF and PSF of bead on plate experiments of second replication
Sample
no.
1
Voltage, V
(V)
Current,
I (A)
Travel
speed, S
(mm/min)
Heat
input (kJ/
mm)
Height of
reinforce
ment, R
(mm)
Weld
bead
width, W
(mm)
Depth of
penetra
tion, P
(mm)
RFF = (W/R)
PSF = (W/P)
22.5
120
390
0.332
2.49
7.83
1.35
3.144
5.8
2
24
140
450
0.358
2.59
8.885
1.41
3.430
6.301
3
24
160
390
0.472
2.455
9.01
1.4
3.670
6.435
4
25
160
390
0.492
2.699
9.83
1.525
3.642
6.445
5
26
180
450
0.499
2.899
10.599
1.599
3.656
6.628
6
28
190
450
0.567
3.01
11.105
1.685
3.689
6.590
7
29
200
480
0.580
3.233
12.785
1.83
3.954
6.986
8
30
220
480
0.660
3.33
13.33
1.85
4.003
7.205
9
31
240
480
0.744
3.265
14.35
1.999
4.395
7.178
The effect of heat input on width of weld bead is shown in Figure 4. The plot is constructed with the
average value of reinforcement as obtained from the two replications of experiments. Dispersion of
width of weld bead (indicating the higher and smaller values) is also indicated at each point of experimental observation. Less dispersion is depicted in Figure 4 showing consistency of replicated experiments. The figure shows that width of weld bead has a clear tendency to increase with increasing
heat input. Higher heat input is related to higher volume of weld pool. As it is bead-on-plate welding,
molten electrode material is expected to spread on the base plate. Therefore, higher heat input causes higher spread of weld material on base plate and hence, higher width of weld bead. In line with
this, for a high value of 0.744 kJ/mm of heat input, width of weld bead is found to be quite high.
The effect of heat input on depth of penetration as observed in bead-on-plate experiments is
shown in Figure 5. Similar to Figures 3 and 4, Figure 5 is plotted with the average value of depth of
penetration as obtained from the two replications of experiments, and its dispersion indicating the
higher and smaller values is also indicated at each point of experimental observation. Depth of penetration shows an overall increase with increasing heat input with small deviations. High heat input
is expected to transfer large amount of heat into the weld zone, and therefore, large depth of penetration is imminent. For this, higher value of 0.744 kJ/mm of heat input gives high depth of penetration of weld bead. Slight decrease in penetration between 0.58 and 0.66 kJ/mm heat input may be
seen for experiments done in the first replication. However, increasing trend is observed in second
replication as usual. Difference in trend in first replication may be the result of experimental deviation that is often experienced.
In Figure 3, minimum slope between experimental points 2 and 3 is observed compared to the
other points. The slope within 8 and 9 points is negative. This may be due to high heat input (0.744 kJ/
3.5
Reinforcement (mm)
Figure 3. Plot of variation of
reinforcement with heat input
as obtained from first and
second replications of bead-onplate experiments.
3.25
3
2.75
2.5
2.25
2
0.3 0.35 0.4 0.45 0.5 0.55 0.6 0.65 0.7 0.75 0.8
Heat Input (kJ/mm)
Page 7 of 14
Figure 4. Plot of variation of
weld bead width with heat
input as obtained from first and
second replications of bead on
plate experiments.
Weld Bead Width (mm)
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15
14
13
12
11
10
9
8
7
0.3 0.35 0.4 0.45 0.5 0.55 0.6 0.65 0.7 0.75 0.8
Heat Input (kJ/mm)
2
Depth of Penetration (mm)
Figure 5. Plot of variation of
depth of penetration with heat
input as obtained from first and
second replications of bead-onplate experiments.
1.9
1.8
1.7
1.6
1.5
1.4
1.3
1.2
0.3 0.35 0.4 0.45 0.5 0.55 0.6 0.65 0.7 0.75 0.8
Heat Input (kJ/mm)
4.6
4.4
4.2
4
RFF
Figure 6. Plot of variation
of RFF with heat input as
obtained from first and second
replications of bead-on-plate
experiments.
3.8
3.6
3.4
3.2
3
0.3 0.35 0.4 0.45 0.5 0.55 0.6 0.65 0.7 0.75 0.8
Heat Input (kJ/mm)
7.5
7.25
7
6.75
PSF
Figure 7. Plot of variation
of PSF with heat input as
obtained from first and second
replications of bead-on-plate
experiments.
6.5
6.25
6
5.75
5.5
0.3 0.35 0.4 0.45 0.5 0.55 0.6 0.65 0.7 0.75 0.8
Heat Input (kJ/mm)
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mm) caused by high weld current and voltage even when weld torch travel speed is high. High torch
travel speed means low time of welding and hence, high heat input taking less time naturally causes
wide weld bead and deep penetration but less height of reinforcement. This is evident from Figures
3 to 5. At point 3, the travel speed is lesser than point two and weld current is higher keeping the
same weld voltage. For this, heat accumulation remains for longer period creating lesser increase in
reinforcement, bead width and penetration.
Variation of change in weld bead geometry with heat input indicates change in deviation from
their linear relationship. It may be the result of usual experimental deviations observed in any experimental investigation.
The effect of heat input on RFF (=weld bead width (W)/height of reinforcement (R)) as observed in
bead-on-plate experiments is shown in Figure 6. In line with previous plots, the plot of Figure 6 is
constructed with the average value of RFF as obtained from the two replications of experiments
against different heat inputs. Dispersion of RFF is indicated at each point of observation. RFF is seen
to increase with increasing heat input on the whole with some deviations. Quite low RFF value is
obtained for minimum heat input of 0.332 kJ/mm used in this work. On the other hand, maximum
RFF is obtained for 0.744 kJ/mm heat input condition. Less dispersion is seen in Figure 6 showing
good consistency of replicated experiments. Large volume of molten material corresponding to
large heat input is expected to cause large spread of weld material due to good wettability of it on
low alloy steel base plate than causing large reinforcement.
The effect of heat input on PSF (=width of weld bead (W)/depth of penetration (P)) as observed in
bead-on-plate experiments is shown in Figure 7. The plot is constructed with the average value of
PSF as obtained from the two replications of experiments. Dispersion of PSF (indicating the higher
and smaller values) is also indicated at each point of experimental observation. The figure shows
that PSF has wide dispersion within 0.5 and 0.6 kJ/mm heat input. Otherwise it increases with increasing heat input. Quite low PSF is obtained for minimum heat input of 0.332 kJ/mm used in this
work. Maximum PSF is obtained for 0.744 kJ/mm heat input condition. Due to large quantity of heat
input and large volume of molten material depositing on base plate in this bead-on-plate experiments, spread of weld pool on base plate is more than the depth of penetration. This condition
would be helpful for doing weld cladding successfully.
The result shows that nature of all graphs (Figure 3 through Figure 7) of first and second replication of bead on plate experiments is somewhat close, barring few deviations. Results of bead-onplate experiments clearly indicate that reinforcement, weld bead width, depth of penetration, RFF
and PSF are significantly influenced by heat input. Maximum reinforcement is obtained in the present experiment at a heat input of 0.660 kJ/mm. At a higher heat input of 0.744 kJ/mm, reinforcement height drops a bit and some spatter is observed. However, depth of penetration and weld bead
width are increased when heat input increases from 0.660 to 0.744 kJ/mm. Considering the above, it
may be recommended that the condition for imparting a heat input of 0.660 kJ/mm can be adopted
in weld cladding practice. In this case, a welding voltage of 30 V, weld current of 220 A and weld
torch travel speed of 480 mm/min are chosen to achieve this heat input condition.
Table 7. ANOVA table on regression analysis relating heat input to weld bead width
df
SS
MS
F
Significance F
Regression
1
71.68677
71.68677
253.2943
3.13E−11
Residual
16
4.52828
0.283018
Total
17
76.21505
Coefficients
Standard error
t Stat
p-value
Lower 95%
Intercept
2.483818
0.539069
4.607609
0.000291
1.341044
X Variable 1
15.96442
1.003091
15.91522
3.13E-11
13.83796
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3.3. Regression analysis
Regression analysis is carried out on the observed data to evaluate the relationship between heat
input and different weld bead geometry parameters. First, weld bead width is tried to express in
terms of heat input. The relation between heat input, Q and weld bead width, W is found out as given
in Equation (4). A simple straight line relation is obtained that signifies increase in weld bead width
with the increase in heat input. This is quite natural a phenomenon in arc welding. Analysis of variance (ANOVA) is done on the regression analysis results and is detailed in Table 7. In this table, Df
stands for degree of freedom, SS is for sum of squares, MS means mean of squares. F corresponds to
F-statistics used in the ANOVA. Clearly high degree of significance at 95% confidence level is found
with respective to regression equation developed.
W = Q × 15.96442 + 2.483818
(4)
Regression equation relating heat input to depth of penetration is developed similar to the previous
case, and the relationship is given as Equation (5). In this case also, simple linear relationship exists
between depth of penetration and heat input to the system during GMAW that is naturally expected.
High heat energy input during arcing is responsible for higher degree of heating and subsequent
melting of electrode material and the portion of base plate. Therefore, higher volume of melting or
weld zone is likely to occur resulting in higher penetration, width or even reinforcement. The procedure of computing significance level of the regression equation evaluated is given in Table 8. High
level of significance is found out regarding the regression equation computed at 95% confidence
level.
The relation between heat input, Q to depth of penetration, P becomes:
P = Q × 1.607342 + 0.832507
(5)
Table 9 shows the ANOVA on regression analysis done to relate heat input with height of reinforcement. At a standard confidence level of 95%, regression equation (Equation 6) is observed to be remarkably significant that means it relates well among heat input and reinforcement. The linear
relationship evaluated is naturally expected.
The relation between height of reinforcement, R and heat input, Q is:
R = Q × 1.824867 + 1.896434
(6)
PSF which is the ratio of weld bead width W, and depth of penetration P, also shows a linear relationship with heat input as par Equation (7). It indicates that with the increase in heat input, weld bead
width increases at a higher rate than the increase in depth of penetration. The test being bead-onplate welding, widening of weld bead is more likely with the increased heat input and increased
melting zone. Table 10 also shows the analysis to be significant at 95% confidence level.
The relation between heat input and PSF becomes:
PSF = Q × 3.278704 + 4.718442
(7)
Regression analysis relating RFF to heat input and its level of significance at 95% confidence level is
shown in Table 11. The regression equation derived as shown in Equation (8) is found to be quite
significant. The relationship is straight linear. It means increase in RFF, that is, the ratio of bead width
to reinforcement height, with heat input to signify higher rate of increase in weld bead width than
reinforcement. This condition is desirable for weld cladding where more bead width than reinforcement or penetration is better related to bond strength and better welding due to more wetting of
weld material to base plate.
Relation between RFF and heat input, Q is given in Equation (8):
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Table 8. ANOVA table on regression analysis relating heat input to depth of penetration
df
SS
MS
F
Significance F
Regression
1
0.72669
0.72669
86.27938
7.59E−08
Residual
16
0.13476
0.008423
Total
17
0.86145
Coefficients
Standard error
t Stat
p-value
Lower 95%
Intercept
0.832507
0.092995
8.952194
1.25E-07
0.635367
X Variable 1
1.607342
0.173043
9.288669
7.59E-08
1.240506
Table 9. ANOVA table on regression analysis relating heat input to height of reinforcement
df
SS
MS
F
Significance F
Regression
1
0.94736
0.94736
17.63854
0.000678742
Residual
16
0.859354
0.05371
Total
17
1.806714
Coefficients
Standard error
t Stat
p-value
Lower 95%
Intercept
1.896434
0.243262
7.795855
7.74E-07
1.380741654
X Variable 1
1.824867
0.43451
4.199826
0.000679
0.903746708
Table 10. ANOVA table on regression analysis relating heat input to PSF
df
SS
MS
F
Significance F
Regression
1
3.023688
3.023688
34.31366
2.43E−05
Residual
16
1.409905
0.088119
Total
17
4.433594
Coefficients
Standard error
t Stat
p-value
Lower 95%
Intercept
4.718442
0.300796
15.6865
3.9E-11
4.080782
X Variable 1
3.278704
0.559717
5.857786
2.43E-05
2.092156
Table 11. ANOVA table on regression analysis relating heat input to RFF
df
SS
MS
F
Significance F
Regression
1
1.795407
1.795407
88.25544
6.5E−08
Residual
16
0.325493
0.020343
Total
17
2.1209
Coefficients
Standard error
t Stat
p-value
Lower 95%
Intercept
2.394495
0.144527
16.56784
1.71E−11
2.088112
X variable 1
2.526476
0.268933
9.394437
6.5E−08
1.956363
RFF = Q × 2.526476 + 2.394495
(8)
In all the regression analyses, straight linear relationships are found that have high degree of significance at 95% confidence level. This justifies the physical understanding that high heat input
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Table 12. Per cent error in estimation of bead geometry parameters
Sample
no.
% Error in
height (R)
% Error in
width (W)
% Error in
depth (P)
% Error in RFF
% Error in PSF
1st
repl
2nd
repl
1st
repl
2nd
repl
1st
repl
2nd
repl
1st
repl
2nd
repl
1st
repl
2nd
repl
1
−2.34
−0.49
−0.12
0.59
−0.82
−1.95
−1.71
−2.84
−1.20
−0.12
2
−4.94
1.55
6.56
7.72
5.19
0.15
8.64
3.82
0.284
6.49
3
−3.48
−12.3
−4.98
−11.2
−2.33
−13.6
−0.19
2.26
−2.19
2.63
4
−0.33
−3.53
−5.65
−5.17
−1.46
−6.45
−3.54
0.12
−3.54
1.76
5
6.44
3.17
1.41
1.41
8.17
−2.22
−3.46
0.02
−6.71
4.22
6
5.45
2.62
−5.01
−3.87
5.34
−3.49
−8.02
−3.74
−10.8
0.19
7
6.19
8.60
2.14
8.15
9.49
3.56
−1.34
2.38
−7.59
5.24
8
5.89
6.88
2.72
2.32
0.3
−2.34
0.01
−1.47
2.317
4.47
9
−1.22
0.33
−0.72
−0.08
−2.19
−1.47
4.10
2.75
0.848
0.28
generates higher pool of weld material that contributes to higher spread or width of weld bead on
the base material. Reinforcement and penetration also increase with heat input, but at a lower rate
than width of weld bead. Therefore, RFF and PSF also show an increasing tendency with the increase
in heat input.
The error analysis on the estimated weld bead geometrical parameters evaluated through regression analysis has been carried out. Their results are shown in Table 12. It is seen that percentage
error is appreciably less in most of the cases, and somewhat high percentage estimation errors
come to be −12.3, −11.2 and −13.6% in case of experiment No. 3 for height of reinforcement, bead
width, and depth of penetration, respectively. Apart from it, in experiment No. 6, only while estimation of PSF, −10.8% error is observed. So, the regression analysis giving somewhat high estimation
error for mainly a particular replication of experiment beyond 10% can be considered to be a fairly
good one.
4. Conclusion
From the observations and regression analysis on the data obtained from bead-on-plate experiments with duplex stainless steel electrode on low alloy steel base plate using GMAW under 100%
carbon dioxide gas shield, the following inferences may be made.
(1) Geometric shape parameters of weld bead like weld bead width, height of reinforcement,
depth of penetration, PSF and RFF are greatly affected by heat input within the range of welding experiments done. In all of the cases, weld bead geometry parameters have linear relationships with heat input.
(2) Higher heat input results in larger quantity of molten weld material, and as it is bead-on-plate
welding, increase in weld bead width in this case is higher due to more spread of weld material
on base plate by good wetting than reinforcement height and depth of penetration.
(3) Heat input of 0.660 kJ/mm may be recommended for adopting in weld cladding practice, as
this condition gives the maximum reinforcement with no spatter and wide weld bead width.
Funding
The authors received no direct funding for this research.
Author details
Ajit Mondal1
E-mail: mondalajit830@gmail.com
Manas Kumar Saha1
E-mail: manassaha71@gmail.com
Ritesh Hazra1
E-mail: zudezhou@whut.edu.cn
Santanu Das1
E-mail: sdas.me@gmail.com
ORCID ID: http://orcid.org/0000-0001-9085-3450
1
Department of Mechanical Engineering, Kalyani Government
Engineering College, Nadia, Kalyani, 741235, West Bengal,
India.
Page 12 of 14
Mondal et al., Cogent Engineering (2016), 3: 1143598
http://dx.doi.org/10.1080/23311916.2016.1143598
Citation information
Cite this article as: Influence of heat input on weld bead
geometry using duplex stainless steel wire electrode on
low alloy steel specimens, Ajit Mondal, Manas Kumar Saha,
Ritesh Hazra & Santanu Das, Cogent Engineering (2016), 3:
1143598.
Cover image
Source: Authors.
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