Abstract
In this work, 6-mm-thick ASTM A387-11–2 steel plates have been butt welded at optimized parametric settings of current (A) = 100 A, voltage (V) = 13 V, and gas flow rate (GFR) = 21 L/min. The as-welded plates have been visually inspected for any surface defects and were found to be defect-free. Further, the weldments were subjected to macroscopic metallography to explore the weld bead geometry. Macroscopic results reveal that the RMD process produces a higher depth of penetration (DOP) and lower heat-affected zone (HAZ) as compared to the GMAW process. Optical and scanning electron microscopy have also been done to examine the internal microstructure in the weldments. The result of microscopic analysis reveals the presence of pearlite and ferrite in the base metal. The process of grain refinement in the heat-affected zone and weld zone was also observed in the form of fine-grain particles which confirms the presence of martensite in the weld zone. In addition to this, the microhardness values for both weldments were measured and compared. The microhardness of GMA weldments was found to be too high in all the zones as compared to that of RMD weldments and hence gives the affirmation with the obtained microstructures in the welded samples.
Similar content being viewed by others
References
J.J. Vora and V.J. Badheka, Experimental Investigation on Effects of Carrier Solvent and Oxide Fluxes in Activated TIG Welding of Reduced Activation Ferritic/Martensitic Steel, Int. J. Adv. Mech. Automobile Eng., 2016, 3, p 75–79.
A. Koprivica, D. Bajić, N. Šibalić, and M. Vukčević, Analysis of welding of aluminium alloy AA6082-T6 by TIG, MIG and FSW processes from technological and economic aspect Analysis of welding of aluminium alloy AA6082-T6 by TIG, MIG and FSW processes from technological and economic aspect, Mach. Technol. Mater., 2020, 5, p 194–198.
D. Patel and S. Jani, Techniques to Weld Similar and Dissimilar Materials by ATIG Welding - An Overview, Mater. Manuf. Processes, 2021, 36, p 1–16. https://doi.org/10.1080/10426914.2020.1802040
F. Rubino, H. Parmar, V. Esperto and P. Carlone, Ultrasonic Welding of Magnesium Alloys: A Review, Mater. Manuf. Processes, 2020, 35, p 1051–1068. https://doi.org/10.1080/10426914.2020.1758330
S. Mandal, S. Joarder, S.M. Murmu, J.J. Tudu, V. Subba and S. Das, Effects of Some Process Parameters on Weld Bead a Brief Investigation, Indian Sci. Cruiser, 2020, 34, p 29–35. https://doi.org/10.24906/isc/2020/v34/i2/196422
S.W. Campbell, A.M. Galloway and N.A. McPherson, Techno-Economic Evaluation on the Effects of Alternating Shielding Gases for Advanced Joining Processes, Proc. Inst. Mech. Eng. Part B J. Eng. Manuf., 2011, 225(10), p 1863–1872. https://doi.org/10.1177/0954405411408353
Dinbandhu, V. Prajapati, J.J. Vora, S. Das and K. Abhishek, Experimental studies of Regulated Metal Deposition (RMDTM) on ASTM A387 (11) Steel: Study of Parametric Influence and Welding Performance Optimization, J. Braz. Soc. Mech. Sci. Eng., 2020, 42, p 1–21. https://doi.org/10.1007/s40430-019-2155-3
A. Rout, D. BBVL, B.B. Biswal, Optimization of process variables of laser sensor assisted robotic GMAW process for mild steel material Mater. Manuf. Processes. (2020) https://doi.org/10.1080/10426914.2020.1784934
D. Bandhu, S. Kumari, V. Prajapati, K.K. Saxena and K. Abhishek, Experimental Investigation and Optimization of RMD™ Welding Parameters for ASTM A387 Grade 11 Steel, Mater. Manuf. Processes, 2021, 36, p 1524–1534. https://doi.org/10.1080/10426914.2020.1854472
V. Prajapati, Dinbandhu, J.J. Vora, S. Das and K. Abhishek, Study of Parametric Influence and Welding Performance Optimization During Regulated Metal Deposition (RMDTM) Using Grey Integrated with Fuzzy Taguchi Approach, J. Manuf. Processes., 2020, 54, p 286–300. https://doi.org/10.1016/j.jmapro.2020.03.017
P. Sharma and D.K. Dwivedi, Comparative Study of Activated Flux-GTAW and Multipass-GTAW Dissimilar P92 Steel-304H ASS Joints, Mater. Manuf. Processes, 2019, 34, p 1195–1204. https://doi.org/10.1080/10426914.2019.1605175
H. Kumar, G.N. Ahmad and N.K. Singh, Activated Flux TIG Welding of Inconel 718 Super Alloy in Presence of Tri-Component Flux, Mater. Manuf. Processes, 2019, 34, p 216–223. https://doi.org/10.1080/10426914.2018.1532581
M. Horvat, V. Kondić and D. Brezovečki, Teorijske i praktične osnove TIG postupka zavarivanja, Tehnički, Glasnik, 2014, 8, p 426–432.
N. Šibalić, M. Vukčević, Research on the Quality of the Welded Joint of Aluminium Alloy Sheet AA6082-T6 Using FSW, MIG and TIG Methods, Materiali in Tehnologije. 53: 711–715 (2019). https://doi.org/10.17222/mit.2018.224
S.W. Shyu, H.Y. Huang, K.H. Tseng and C.P. Chou, Study of the Performance of Stainless Steel A-TIG Welds, J. Mater. Eng. Perform., 2008 https://doi.org/10.1007/s11665-007-9139-7
Cynthia L. Jenney, Annette O’Brien, Welding Handbook, 8th ed., (American Welding Society, 1987) https://doi.org/10.1007/978-1-349-10624-0.
R. Sudhakar, R. Sivasubramanian and J. Yoganandh, Effect of Automated MIG Welding Process Parameters on ASTM A 106 Grade B Pipe Weldments used in High-Temperature Applications, Mater. Manuf. Processes, 2018, 33(7), p 749–758. https://doi.org/10.1080/10426914.2017.1401719
S. Das, J.J. Vora and V. Patel, Regulated Metal Deposition (RMDTM) Technique for Welding Applications: An Advanced Gas Metal Arc Welding Process, Advances in Welding Technologies for Process Development. CRC Press, USA, 2019, p 23–32
J. Cuhel, Modified GMAW for Root Passes, TPJ-The Tube & Pipe Journal®. 1–4 (2008)
M. Roth, Shinn Mechanical Uses PipeWorx Welding System to Increase Pipe Fabrication Quality and Productivity, Miller Electric Mfg. LLC. 1–4, (2009)
M. Roth, Graham Corporation Meets Reduced Rework Objectives with Help from Miller’s PipeWorx TM Welding Systems, (2018)
J. Cuhel, K. Packard, RMD® Short-Circuit Metal Transfer, Pulsed MIG Processes with Metal-Cored Wires Improve Pipe Fabrication for Swartfager Welding, Inc., Miller Electric Mfg. LLC. 1–8, (2009)
L.A. do Nascimento, L.O. Vilarinho, Evaluation of GMAW Processes GMAW Controlled Short-Circuit Transfer (STT) applied To Mechanized Girth Welding, in: Congresso Nacional de Engenharia Mecânica Fortaleza/CE, 1–16, (2016)
Dinbandhu, V. Prajapati, J.J. Vora and K. Abhishek, Advances in gas metal arc welding process: modifications in short-circuiting transfer mode, Adv. Weld. Deform., 2021 https://doi.org/10.1016/b978-0-12-822049-8.00003-7
F. Kolahan and M. Heidari, A New Approach for Predicting and Optimizing Weld Bead Geometry in GMAW, World Acad. Sci. Eng. Technol., 2009, 59, p 138–141. https://doi.org/10.5281/zenodo.1081164
Y.S. Tarng and W.H. Yang, Optimisation of the Weld Bead Geometry in Gas Tungsten Arc Welding by the Taguchi Method, Int. J. Adv. Manuf. Technol., 1998, 14, p 549–554. https://doi.org/10.1007/BF01301698
S.K. Gupta, S. Mehrotra, A.R. Raja, M. Vashista and M.Z.K. Yusufzai, Effect of Welding Speed on Weld Bead Geometry and Percentage Dilution in Gas Metal Arc Welding of SS409L, Mater. Today Proc., 2019, 18, 5032–5039. https://doi.org/10.1016/j.matpr.2019.07.497
P.E. Murray and A. Scotti, Depth of Penetration in Gas Metal Arc Welding, Sci. Technol. Weld. Joining, 1999, 4, p 112–117. https://doi.org/10.1179/136217199101537644
K. Deb, Multi-Objective Optimization using Evolutionary Algorithms, John Wiley & Sons, Ltd., New Jersey, USA, 2001.
K. Deb, Optimization for Engineering Design-Algorithms and Examples, 2nd ed. PHI Learning Private Limited, New Delhi, 2012.
E.K.P. Chong and S.H. Zak, An Introduction to Optimization, IEEE Antennas Propag. Mag., 1996, 38, p 60. https://doi.org/10.1109/MAP.1996.500234
U.M. Diwekar, Introduction to Applied Optimization, Springer, Boston, 2003. https://doi.org/10.1007/978-1-4757-3745-5
S. Chatterjee, S.S. Mahapatra, L. Lamberti and C.I. Pruncu, Prediction of Welding Responses Using AI Approach: Adaptive Neuro-Fuzzy Inference System and Genetic Programming, J. Braz. Soc. Mech. Sci. Eng, 2022 https://doi.org/10.1007/S40430-021-03294-W
S. Chatterjee, S.S. Mahapatra, V. Bharadwaj, B.N. Upadhyay and K.S. Bindra, Prediction of Quality Characteristics of Laser Drilled Holes Using Artificial Intelligence Techniques, Eng. Computers, 2021, 37, p 1181–1204. https://doi.org/10.1007/S00366-019-00878-Y/TABLES/9
S. Chatterjee, S.K. Sahoo, B. Swain, S.S. Mahapatra and T. Roy, Quality Characterization of Dissimilar Laser Welded Joints of Ti6Al4V with AISI 304 by Using Copper Deposition Technique, Int. J. Adv. Manuf. Technol., 2020, 106, p 4577–4591. https://doi.org/10.1007/S00170-020-04935-5/FIGURES/25
D. Bandhu, J.J. Vora, S. Das, A. Thakur, S. Kumari, K. Abhishek and M.N. Sastry, Experimental Study on Application of Gas Metal Arc Welding Based Regulated Metal Deposition Technique for Low Alloy Steel, Mater. Manuf. Processes., 2022 https://doi.org/10.1080/10426914.2022.2049298
J.P. Mistry, Effect of Process Parameters on Bead Geometry and Shape Relationship of Gas Metal Arc Weldments, International J. Adv. Res. Mech. Eng. Technol. (IJARMET). 2, 24–27 (2016). www.ijarmet.com (accessed March 4, 2021).
M. Nouri, A. Abdollah-Zadeh, F. Malek, Effect of welding parameters on dilution and weld bead geometry in cladding, J. Mater. Sci. Technol. 23, 817–822 (2007). https://www.jmst.org/CN/ (accessed March 4, 2021).
R. Darji, V. Badheka, K. Mehta, J. Joshi and A. Yadav, Processing of Copper by Keyhole Gas Tungsten Arc Welding for Uniformity of Weld Bead Geometry, Mater. Manuf. Processes, 2020 https://doi.org/10.1080/10426914.2020.1784932
S. Datta, M.S. Raza, P. Saha and D.K. Pratihar, Effects of Process Parameters on the Quality Aspects of Weld-Bead in Laser Welding of NiTinol Sheets, Mater. Manuf. Processes, 2019, 34, p 648–659. https://doi.org/10.1080/10426914.2019.1566608
S.K. Sharma, S. Maheshwari and R.K.R. Singh, Effect of Heat-Input and Cooling-Time on Bead Characteristics in SAW, Mater. Manuf. Processes, 2019, 34, p 208–215. https://doi.org/10.1080/10426914.2018.1532578
S. Mandal, S. Kumar, P. Bhargava and C.P. Paul, Analysis of Discontinuous Bead Formation by PTAW Process, Mater. Manuf. Processes, 2016, 31, p 2181–2185. https://doi.org/10.1080/10426914.2016.1198020
A. Choudhary, M. Kumar and D.R. Unune, Experimental Investigation and Optimization of Weld Bead Characteristics During Submerged Arc Welding of AISI 1023 Steel, Def. Technol., 2019, 15, p 72–82. https://doi.org/10.1016/j.dt.2018.08.004
D.K. Choudhary, S. Jindal and N.P. Mehta, To Study the Effect of Welding Parameters on Weld Bead Geometry in SAW Welding Process, Elixir Mech. Engg., 2011, 40, p 5519–5524. https://doi.org/10.4236/jmmce.2011.109064
P. Kumari, K. Archna and R.S. Parmar, Effect of Welding Parameters on Weld Bead Geometry in MIG Welding of Low Carbon Steel, J. Mater. Sci. Technol., 2007, 23, p 249–258.
S. Das, J.J. Vora, V. Patel, W. Li, J. Andersson, D.Y. Pimenov, K. Giasin and S. Wojciechowski, Experimental Investigation on Welding of 2.25 Cr-1.0 Mo Steel with Regulated Metal Deposition and GMAW Technique Incorporating Metal-Cored Wires, J. Mater. Res. Technol., 2021, 15, p 1007–1016. https://doi.org/10.1016/j.jmrt.2021.08.081
D. Bandhu and K. Abhishek, Assessment of Weld Bead Geometry in Modified Shortcircuiting Gas Metal Arc Welding Process for Low Alloy Steel, Mater. Manuf. Processes, 2021, 36, p 1384–1402. https://doi.org/10.1080/10426914.2021.1906897
Dinbandhu, K. Abhishek, Parametric Optimization and Evaluation of RMDTM Welding Performance for ASTM A387 Grade 11 Steel Plates Using TOPSIS-Taguchi Approach, in: Advances in Materials Processing and Manufacturing Applications. ICADMA 2020. Lecture Notes in Mechanical Engineering. Springer, Singapore, 2021: pp. 215–227. https://doi.org/10.1007/978-981-16-0909-1_22.
G. Ma, H. Yuan, L. Yu and Y. He, Monitoring of Weld Defects of Visual Sensing Assisted GMAW Process with Galvanized Steel, Mater. Manuf. Processes., 2021 https://doi.org/10.1080/10426914.2021.1885711
A.K. Pandey, P.M. Pandey and S. Pandey, Control of Weld Distortion Through in-situ Preheating of Weld Filler Wire, Mater. Manuf. Processes, 2020 https://doi.org/10.1080/10426914.2020.1866194
Y. Koli, N. Yuvaraj and S. Aravindan, Investigations on Weld Bead Geometry and Microstructure in CMT, MIG Pulse Synergic and MIG Welding of AA6061-T6, Mater. Res. Exp., 2019, 6, p 126. https://doi.org/10.1088/2053-1591/ab61b6
U. Esme, M. Bayramoglu, Y. Kazancoglu and S. Ozgun, Optimization of Weld Bead Geometry in Tig Welding Process Using Grey Relation Analysis and Taguchi Method, Mater. Technol., 2009, 43, p 143–149.
A. Bhattacharya and T.K. Bera, Development of Automatic GMAW Setup for Process Improvements: Experimental and Modeling Approach, Mater. Manuf. Processes, 2014, 29, p 988–995. https://doi.org/10.1080/10426914.2014.892611
K. Devakumaran, N. Rajasekaran and P.K. Ghosh, Process Characteristics of Inverter Type GMAW Power Source Under Static and Dynamic Operating Conditions, Mater. Manuf. Processes, 2012, 27, p 1450–1456. https://doi.org/10.1080/10426914.2012.663149
Z. Zhang and X. Kong, Study on DC Double Pulse Metal Inert Gas (MIG) Welding of Magnesium Alloy, Mater. Manuf. Processes, 2012 https://doi.org/10.1080/10426914.2011.585500
J. Luo, Q. Luo, X. Wang and X. Wang, EMS-CO2 Welding: A New Approach to Improve Droplet Transfer Characteristics and Welding Formation, Mater. Manuf. Processes, 2010, 25, p 1233–1241. https://doi.org/10.1080/10426914.2010.481000
What is Weld Spatter? | OTC DAIHEN, (n.d.). https://www.daihen-usa.com/weld-spatter/ (accessed March 17, 2021)
J.J. Vora and V.J. Badheka, Experimental Investigation on Microstructure and Mechanical Properties of Activated TIG Welded Reduced Activation Ferritic/Martensitic Steel Joints, J. Manuf. Process., 2017, 25, p 85–93. https://doi.org/10.1016/j.jmapro.2016.11.007
J.J. Vora and V.J. Badheka, Improved Penetration with the Use of Oxide Fluxes in Activated TIG Welding of Low Activation Ferritic/Martensitic Steel, Trans. Indian Inst. Met., 2016, 69, p 1755–1764. https://doi.org/10.1007/s12666-016-0835-6
J.J. Vora and V.J. Badheka, Experimental Investigation on Mechanism and Weld Morphology of Activated TIG Welded Bead-on-Plate Weldments of Reduced Activation Ferritic/Martensitic Steel Using Oxide Fluxes, J. Manuf. Process., 2015, 20, p 224–233. https://doi.org/10.1016/j.jmapro.2015.07.006
T.F. Costa, L.O. Vilarinho, Influence of Process Parameters During the Pipe Welding of Low-Carbon Steel Using RMD (Regulated Metal Deposition) Process, in: Proceedings of COBEM 2011; 21st Brazilian Congress of Mechanical Engineering Copyright © 2011 by ABCM October 24–28, 2011, (Natal, RN, Brazil), 2011: pp. 1–10.
Miller Welds, New regulated metal deposition (RMDTM) MIG welding process improves stainless steel pipe fabrication, Miller Electric Mfg. LLC. (2017) 1–8. https://www.millerwelds.com/resources/article-library/new-regulated-metal-deposition-rmd-mig-welding-process-improves-stainless-steel-pipe-fabrication.
J. Cuhel, D. Benson, Welding stainless steel tube and pipe: maintaining corrosion resistance and increasing productivity, Miller Electric Mfg. LLC. (2009) 1–4.
B. Yang, W.C. Jiang, W.Q. Sun, Y.L. Zhao, W.Y. Zhang, Microstructure and tensile properties of a 1.25Cr-0.5Mo main steam pipe after long-term service, in: American Society of Mechanical Engineers, Pressure Vessels and Piping Division (Publication) PVP, American Society of Mechanical Engineers (ASME), (2018) https://doi.org/10.1115/pvp2018-84185.
K. Prasad and D.K. Dwivedi, Microstructure and Tensile Properties of Submerged Arc Welded 1.25Cr-0.5Mo Steel Joints, Mater. Manuf. Processes., 2008, 23, p 463–468. https://doi.org/10.1080/10426910802103551
S.K. Das, A. Joarder and A. Mitra, Magnetic Barkhausen emissions and microstructural degradation study in 1.25 Cr-0.50 Mo steel during high temperature exposure, NDT E Int., 2004, 37, p 243–248. https://doi.org/10.1016/S0963-8695(03)00032-X
K. Prasad and D.K. Dwivedi, Some Investigations on Microstructure and Mechanical Properties of Submerged Arc Welded HSLA Steel Joints, Int. J. Adv. Manuf. Technol., 2008, 36, p 475–483. https://doi.org/10.1007/s00170-006-0855-1
H. Cetine and M. Ayvaz, Microstructure and Mechanical Properties of AA 5083 and AA 6061 Welds Joined with Alsi5 and Alsi12wires, Materialpruefung/Mater Test, 2014 https://doi.org/10.3139/120.110647
C.H. Hung, W.T. Chen, M.H. Sehhat and M.C. Leu, The Effect of laser Welding Modes on Mechanical Properties and Microstructure of 304L Stainless Steel Parts Fabricated by Laser-Foil-Printing Additive Manufacturing, Int. J. Adv. Manuf. Technol., 2021, 112, p 867–877. https://doi.org/10.1007/s00170-020-06402-7
E. Taban, Joining of Duplex Stainless Steel by Plasma Arc, TIG, and Plasma Arc+TIG Welding Processes, Mater. Manuf. Processes, 2008, 23, p 871–878. https://doi.org/10.1080/10426910802385075
R. Manti and D.K. Dwivedi, Microstructure of Al-Mg-Si Weld Joints Produced by Pulse TIG Welding, Mater. Manuf. Processes, 2007, 22, p 57–61. https://doi.org/10.1080/10426910601015923
S. Tathgir, A. Bhattacharya and T.K. Bera, Influence of Current and Shielding Gas in TiO2 Flux Activated Tig Welding on Different Graded Steels, Mater. Manuf. Processes, 2015, 30, p 1115–1123. https://doi.org/10.1080/10426914.2014.973591
S. Tathgir and A. Bhattacharya, Activated-TIG Welding of Different Steels: Influence of Various Flux and Shielding Gas, Mater. Manuf. Processes, 2016, 31, p 335–342. https://doi.org/10.1080/10426914.2015.1037914
B.K. Khamari, P. Kumar Sahu and B.B. Biswal, Microstructure Analysis of Arc Welded Mild Steel Plates, IOP Conf. Series Mater. Sci. Eng., 2018 https://doi.org/10.1088/1757-899X/377/1/012049
R. Singh, B. Prasad and B.N. Rai, Effect of Parameters Involved in Arc Welded Mild Steel Plates, IOP Conf. Series Mater. Sci. Eng., 2018 https://doi.org/10.1088/1757-899X/377/1/012179
N.R. Jesudoss Hynes, P. Nagaraj and J.A. Jennifa Sujana, Investigation on Joining of Aluminum and Mild Steel by Friction Stud Welding, Mater. Manuf. Processes., 2012, 27, p 1409–1413. https://doi.org/10.1080/10426914.2012.667894
R. Kumar, A. Bhattacharya and T.K. Bera, Mechanical and Metallurgical Studies in Double Shielded GMAW of Dissimilar Stainless Steels, Mater. Manuf. Processes, 2015, 30, p 1146–1153. https://doi.org/10.1080/10426914.2014.994760
A.K. Lakshminarayanan, V. Balasubramanian and M. Salahuddin, Microstructure, Tensile and Impact Toughness Properties of Friction Stir Welded Mild Steel, J. Iron Steel Res. Int., 2010, 17, p 68–74. https://doi.org/10.1016/S1006-706X(10)60186-0
I.A. Ibrahim, S.A. Mohamat, A. Amir and A. Ghalib, The Effect of Gas Metal Arc Welding (GMAW) Processes on Different Welding Parameters, Procedia Eng., 2012, 41, p 1502–1506. https://doi.org/10.1016/j.proeng.2012.07.342
Acknowledgments
The authors would like to thank ITW India Private Ltd.-Welding Group, Vadodara, Gujarat, for their dynamic cooperation in the experiments.
Author information
Authors and Affiliations
Corresponding author
Ethics declarations
Conflict of interest
The authors state that they have no known competing financial interests or personal ties that may seem to have influenced the study presented in this article.
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
Springer Nature or its licensor holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.
About this article
Cite this article
Bandhu, D., Goud, E.V., Vora, J.J. et al. Influence of Regulated Metal Deposition and Gas Metal Arc Welding on ASTM A387-11–2 Steel Plates: As-deposited Inspection, Microstructure, and Mechanical Properties. J. of Materi Eng and Perform 32, 1025–1038 (2023). https://doi.org/10.1007/s11665-022-07185-6
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11665-022-07185-6