UNIVERSITI TECHNOLOGY MALAYSIA

FACULTI KEJURUTERAAN MEKANIKAL

PROJEK SARJANA MUDA 1

(SMJ 4912)

10 MAY 2009
SUBMERG ARC WELDING EVOLUTION OF
CARBON STEEL PLATE

NAMA : ZAINAL ABIDDIN SHAH BIN MATTAR

METRIC NO: SX045349MMD04

I/C NO : 650419-04-5297

SUPERVISOR: PM ZAINAL ABIDIN BIN AHMAD

 Gantt Chart PSM 1

WORK ACTIVITY Weeks

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Topic Selection

To identify / study the

scope of experiment

Literature survey the

process of SAW,
historical, machines,
application and process
parameter
Literature the recent
development and the
problem facing
Collect information / data
from literature review

Prepare suitable
standard & procedure.

Prepare drat for report

Preparation final report

PSM Presentation
 Contents

INTRODUCTION

OBJECTIVE

SCOPE

METHODOLOGY

EXPERIMENTAL PROCEDURE

CONCLUSION
 Introduction

 Carbon Steel A36 steel is a standard steel alloy which is a

common structural steel used.
 A36 has a density of 0.28 lb/in³ (7.8 g/cm³).
 A36 steel in plates, bars and shapes with a thickness of less than
8 in (200 mm) has a minimum yield strength of 36,000 psi
(250 MPa) and ultimate tensile strength of 58,000–80,000 psi (400–
550 MPa)
 Plates thicker than 8 in have a 32,000 psi (220 MPa) yield strength
and the same ultimate tensile strength. (Metal Handbook ASM,
1983)
 A36 is a standard carbon steel without advanced alloying
 Carbon steel plate has wide application. It extensively used in
heavy fabrication industries like ship, locomotives, bridge
structure and pressure vessel construction.
Chemical compositions of the base material and filler material
(mass %)

C Mn S P Si Cu

Carbon steel ASTM 36 0.25 0.80 0.05 0.04 0.4 0.2

Filler metal AWS 5.17 0.10 0.25 0.07 0.03 0.07 0.35
 Example: Steel Structure Fabrication

Steel Tower Bridge

Building & Industry

Equipments for Submerge Arc Welding
Schematic Saw Processes
 OBJECTIVE

To find out the optimal welding process parameter of

Submerge Arc Welding such as arc current, arc voltage,
welding speed and wire stick-out and their interactions
play a significant role for four mechanical performance
characteristics such as tensile, hardness, deposition
rate and dilution on carbon steel ASTM 36.
 SCOPE

 Experiment using Carbon steel Plate A36 and the specimen

to be weld using Submerge Arc Welding Machine

 Two range (lower level & upper level ) from four parameter
of submerge arc welding was decide as a scope of testing.

 Orthogonal array for L8 (27) Taguchi design was chosen

 Tensile test , Hardness test, Dilution and Deposition was

selected as mechanical properties testing.
 METHODOLOGY

 This project will be conducted through the experimental /

testing using Submerge Arc Welding Machine. ( Austcorp.
Manufacturing – DC 1300 )

 Taguchi method was selected as a design experiments. This

method use a special set of arrays called orthogonal arrays.
Develop by Dr. Genichi Taguchi a Japanese quality management
consultant (Peace, G.S, 1993)
 METHODOLOGY

 The data from experiment will be analyze by 2 software ;

1. MINITAB Software - Minitab is a statistical program with

a spreadsheet-like data worksheet. It is capable of
manipulating and transforming the data and can
produce graphical and numerical summaries.

2. Analysis of variance (ANOVA) - An ANOVA is an analysis

of the variation present in an experiment. The method is
very useful to reveal the level of significance of influence
of factor's or interaction of factors on a particular
response
 Start

Prepare specimens.
(Carbon Steel A36)

Submerge Arc welding machine setting. Four

parameter and 2 level of range was selected

Weld specimens using Taguchi method L8(27)

Mechanical
Properties Test

Tensile Test Hardness Test Deposition DilutionTest

Micro
Structure
Check
Collect Data Collect Data Collect Data Collect Data

Analysis data using MINITAB & ANOVA method

Finish
 Experimental procedure.

 The base material employed in this study is 10 mm-thick Carbon Steel A36
welded with AWS 5.17 filler material.

 The base metal sheets of dimension 300×100×10mm have been prepared

and butt joints were made using the experimental layout shown

 Prior to welding, the base metal sheets were pickled with a solution of
NaOH and HNO3, wire brushed, and degreased using acetone, and finally
preheated to 100°C

 The sheets to be welded were kept on a copper backing bar and the ends
were clamped to maintain the alignment and gap

 Specimens for tensile testing were taken at the middle of all the joints and
machined to ASTM E8 standards (ASTM Standard Handbook, 2004). The
configuration of the specimens used for plain tensile test.
 Specimens for metallographic observation and micro hardness tests (15-mm width) were
taken at the middle of all the joints.

 Micro-hardness tests were carried out on the welded samples with a load of 15 g and a
duration of 15 s using a Vickers digital micro-hardness tester

 Weld metal dilution (i.e., volume fraction of the base metal into the weld bead) was
evaluated in terms of area fraction (assumed to represent volume fraction) as follows

Weld metal dilution (%) = Ab / Aw x 100

Where;

Ab = The cross section area of the base metal melted

Aw = Cross-sectional area of the weld bead including reinforcement.

 Deposition Rate Formula

Wire speed (IPM) x 60 minute x Lbs. per foot ) = Deposition rate

12 inches

Example using 3/32” wire:

125 IPM = 10.4 x 60 (min) =625 x 0.23 (chart) = 14.4 Ibs. per. hour
12”
Scheme of welding with respect to rolling
direction and extraction of tensile
Layout of tensile specimen
Working range of the process parameter

Symbol Process Units Lower Level Upper Level

Parameter (1) (2)

A Arc Current Amp 400 500

B Arc Voltage V 26 30

C Welding Speed mm/sec 30 40

D Electrode Stick-out mm 19 25
Orthogonal array for L8 (27) Taguchi design

Exp.no . A B AxB C AxC BxC D

P1 1 1 1 1 1 1 1
P2 1 1 1 2 2 2 2
P3 1 2 2 1 1 2 2
P4 1 2 2 2 2 1 1
P5 2 1 2 1 2 1 2
P6 2 1 2 2 1 2 1
P7 2 2 1 1 2 2 1
P8 2 2 1 2 1 1 2
Mechanical Properties of Carbon Steel A36

Specimen Tensile strength (Mpa) Micro Hardness (HV) Dilution (%)

ID Trial 1 Trial 2 Trial 1 Trial 2 Trial 1 Trial 2

P1 x1 x2 x1 x2 x1 x2

P2 x1 x2 x1 x2 x1 x2

P3 x1 x2 x1 x2 x1 x2

P4 x1 x2 x1 x2 x1 x2

P5 x1 x2 x1 x2 x1 x2

P6 x1 x2 x1 x2 x1 x2

P7 x1 x2 x1 x2 x1 x2

P8 x1 x2 x1 x2 x1 x2

Base metal x1 x2 x1 x2 x1 x2
 CONCLUSION

 In this study, an attempt will be made to determine important welding

process parameters for the four performance characteristics, tensile,
hardness, deposition rate and dilution in the SAW process.

 Factors such as arc current, arc voltage and welding speed and their
interactions play a significant role in the SAW process.

 Taguchi’s experimental design strategy was applied to obtain optimum

welding-process-parameter combinations for each of the performance
criteria – maximization of deposition rate, minimization of dilution and
maximization of hardness.

 The analysis was further supplemented by a more rigorous statistical

analysis known as ANOVA and MINITAB
Thank You
QUESTION

&
ANSWER