A MINOR PROJECT PROGRESS REPORT

TO STUDY THE INFLUENCE OF DIFFERENT COOLING

MEDIA ON MECHANICAL PROPERTIES OF GAS
TUNGSTEN INERT WELDED TOOL STEELS

PRESENTED BY : UNDER GUIDANCE OF

VIKAS MANI TRIPATHI GUIDE

00370218617 PROF. (DR.) SAGAR MAJI
M.TECH (TOOL ENGINEERING) CO- GUIDES
MR. RAHUL KATNA
MR. PRAVEEN KUMAR
CONTENTS
1. INTRODUCTION
2. LITERATURE REVIEW
3. GAPS IDENTIFIED
4. OBJECTIVES FOR MINOR PROJECT
5. OBJECTIVE FOR MAJOR PROJECT
6. METHODOLOGY
7. PROGRESS
8. REFERENCES
 INTRODUCTION

■ Welding is a fabrication or sculptural process that joins materials,

usually metals or thermoplastics by causing fusion, which is distinct
from lower temperature metal-joining techniques such as brazing and
soldering, which do not melt the base metal.
■ In addition to melting the base metal, a filler material is typically
added to the joint to form a pool of molten material (the weld pool)
that cools to form a joint that is usually stronger than the base
material.
■ Pressure may also be used in conjunction with heat, or by itself, to
produce a weld. Although less common, there are also solid state
welding processes such as friction welding or shielded active gas
welding in which metal does not melt.
■ Some of the best known welding methods include:
■ Shielded metal arc welding (SMAW) – also known as "stick welding or electric
welding", uses an electrode that has flux around it to protect the weld puddle. The
electrode holder holds the electrode as it slowly melts away. Slag protects the weld
puddle from atmospheric contamination.
■ Gas tungsten arc welding (GTAW) – also known as TIG (tungsten, inert gas), uses a
non-consumable tungsten electrode to produce the weld. The weld area is protected
from atmospheric contamination by an inert shielding gas such as argon or helium.
■ Gas metal arc welding (GMAW) – commonly termed MIG (metal, inert gas), uses a
wire feeding gun that feeds wire at an adjustable speed and flows an argon-based
shielding gas or a mix of argon and carbon dioxide (CO2) over the weld puddle to
protect it from atmospheric contamination.
■ Flux-cored arc welding (FCAW) – almost identical to MIG welding except it uses a
special tubular wire filled with flux; it can be used with or without shielding gas,
depending on the filler.
■ Submerged arc welding (SAW) – uses an automatically fed consumable electrode
and a blanket of granular fusible flux. The molten weld and the arc zone are
protected from atmospheric contamination by being "submerged" under the flux
blanket.
GTAW (GAS TUNGSTEN ARC WELDING)
■ TIG Welding is a manual welding process that requires the welder to use two hands to
weld. What separates TIG welding from most other welding processes is the way the arc
is created and how the filler metal is added.
■ When TIG Welding one hand is used for holding the TIG torch that produces the arc and
the other hand is to add the filler metal to the weld joint. Because two hands are
required to weld; TIG welding is the most difficult of the processes to learn, but at the
same time is the most versatile when it comes to different metals.
■ . TIG welding is mostly used for critical weld joints, welding metals other than common
steel, and where precise, small welds are needed.
■ TIG welding requires three thing, heat, shielding, and filler metal. The heat is produced
by electricity passing through the tungsten electrode by creating an arc to the metal. The
shielding comes from a compressed bottle of gas that flows to the weld area to protect it
from air. The filler metal is just a wire that is dipped by hand into the arc and melted.
■ Since Argon and Helium are Nobel inert gasses they do not change the characteristics of
the weld joint. In some cases there are three types of mixture used. The first is Argon
and hydrogen and the second is Argon and Nitrogen. The third mixture is Argon and
Helium and that is typically used on thicker metals to get deeper weld penetration. In
most cases pure Argon will cover almost all welding needs.
LITERATURE REVIEW
Many researchers and academicians of international repute have probed into the topic
of study of effect of welding parameters their name and work has been given below:-
■ Das et al. welded EN-3A mild steel specimens by metal inert gas welding and showed the effect of
various welding process parameters on its weldability. Parameters selected were welding current,
arc voltage and welding speed. A butt joint was prepared and depth of penetrations was measured.
Effect of welding parameters on penetration was observed with the help surface plots.
■ Juang et al. studied the process parameter selection for optimizing the weld pool geometry in the
tungsten inert gas welding of stainless steel. Basically, the geometry of the weld pool has several
quality characteristics, for example, the front height, front width, back height and back width of
the weld pool. To consider these quality characteristics together in the selection of process
parameters, the modified Taguchi method is adopted to analyze the effect of each welding process
parameter on the weld pool geometry, and then to determine the process parameters with the
optimal weld pool geometry.
■ Ul-Hamid, et al. showed Failure of weld joints between carbon steel pipe and 304
stainless steel elbows. This paper has presented the comparison between SMAW
and GTAW techniques to built a stronger dissimilar metal joint
■ Palanivendhan ET AL. investigated the mechanical properties and microstructure of
TIG welded D2-SS samples by varying welding torch angle, current, voltage,feed and
speed.
■ Raza et al. did a review of different welding processes and their effect on
microstructure , grain refinement and tensile strength of materials such as
stainless steel, low carbon alloy steel and low carbon steel.
■ Zang et al. conducted a comparative study on microstructure changes and
properties of forced water cooled and air cooled friction stir welded ultra high
nitrogen stainless steel specimens, in which it is found that water cooled specimen
has refines grain structure and higher tensile strength as compared to air cooled
specimen.
■ Dutta et al studied Microstructure, hardness and wear behaviour of AISI D2 steel
subjected to varied sub-zero treatments that have been examined with reference to
conventional heat treatment. The developed microstructure has been characterized
by Optical microscopy, SEM examination and the further image analysis.
■ Singh et al did a review of cryoprocessing and its effects on tool steels and carbides,
metallurgical aspects including reduced amount of retained austenite, precipitation of η-
carbides, phase change in carbides, improvement in wear resistance, and applications
are reviewed for manufacturing industry.
■ Mollinary et al experimented and showed the effect of deep cryogenic treatment on the
properties of quenched tool steel that was studied using field tests and laboratory tests.
■ Chen et al conducted an experimental study on process-induced residual stresses in
laser clad AISI P20 tool steel onto pre-hardened wrought P20 base material and the
correlation with microstructures using X-ray diffraction and scanning electron
microscopic analyses, the roles of solid-state phase transformations in the clad and
heat-affected zone (HAZ) of the substrate during cladding and post-cladding heat
treatments on the development and controllability of residual stresses in the P20 clad.
■ Newishy et al. experimented and researched the scope of improvement of surface
hardness and wear properties. Characterizing the LSM, with optical and field emission
scanning electron microscopy, and surface hardness technique was used to evaluate the
micro-hardness and mechanical behaviour of different regions of melting pool.
■ .Orr et al conducted a research to investigate the effect on weld metal microstructure
and solidification cracking susceptibility. Weld samples were prepared with different
argon-nitrogen shielding gas mixtures to produce nitrogen variations in the weld metal.
The cast pin tear test (CPTT) was then used to evaluate solidification cracking
susceptibility as a function of weld metal nitrogen content. Phase fraction and
composition of constituents in the final solidification microstructure were characterized
via optical and electron microscopy.
■ Bithras et al studied the effect of alternating gases to study the effect on arc and weld
parameters. A schlieren system was used to image density gradients that arise when
alternating argon and helium shield gases, under varying flow parameters, with gas
tungsten arc welding (GTAW). A theoretical analysis was carried out to determine the
conditions under which the technique facilitates arc pulsing, in particular to avoid mixing
of the shield gases in the delivery pipe prior to the welding nozzle. At appropriate pulsing
frequency and flow rates, a stable horizontal region of helium was observed in the weld
region, maintained in position by the denser argon from the preceding pulse.Weld
penetration increased by 13%.
■ Mulc et al studies the impact toughness of weld deposits of H13 hot working tool steel.
Charpy test was conducted on samples of H13 steel welded using different filler
materials alloyed with some elements. Experimental results have shown that the
appropriate choice of filler metal is the most important factor for the adequate
preparation of HWTS repair welding, with filler material alloyed with vanadium being
toughest and hardest.
■ Khalid rafi et al. studied the microstructural evolution during frictional surfacing of tool
steel H13. Coatings of AISI H13 tool steel were made on low carbon steel by friction
surfacing. Detailed microstructural studies and microhardness tests were carried out on
the coatings. Studies revealed defect-free coatings and sound metallurgical bonding
between the coating and the substrate. In addition, mechanical interlocking on a very
fine scale was observed to occur between the coating and the substrate.
■ Mani et al conducted a study on corrosion resistance of dissimilar welding of 316L steel and
monel 400. by GTAW process. The present research paper contributes to the ongoing research
work on the use of Monel400 and 316L austenitic stainless steel in industrial environments.
Potentiodynamic method is used to investigate the corrosion behavior of Monel 400 and 316L
austenitic stainless steel welded joints. The analysis has been performed on the base metal, heat
affected zone and weld zone after post weld heat treatment. Optical microscopy was also
performed to correlate the results.
■ Ning et al studied the precipitation behaviour of carbides in H13 die steel and its strengthening
during tempering. The properties of carbides, such as morphology, size, and type, in H13 hot work
die steel were studied with optical microscopy, transmission electron microscopy, electron
diffraction, and energy dispersive X-ray analysis; their size distribution and quantity after tempering,
at different positions within the ingot, were analyzed using Image-Pro Plus software. Two kinds of
carbide precipitates have been detected in H13: (1) MC and M6C, generally smaller than 200 nm;
and (2) M23C6, usually larger than 200 nm. MC and M6C play the key role in precipitation
hardening.
■ Suarez et al . studied the different arc welding procedures for mould and tool steels. aims to
present a method to establish arc welding procedures on steels for moulds and dies. The
welding of AISI P20 steel was studied. Simple and multi-pass welding were undertaken using
the Tungsten inert gas process, evaluating the bead geometry, hardness distribution,
microstructure and quality features after grinding, polishing and texturing. By the bead
implant test and analytical heat transfer solutions, multi-pass welding techniques were
optimized to cause the tempering effect to the weld metal and heat affected zone by a second
thermal cycle of welding.
GAPS IDENTIFIED
■ There is very less amount of work and reported research that has been done on the
weldability of tool steels, especially those involving TIG process.
■ Most of the cryogenic experiments have only been conducted on D2 and its
dissimilar joints with other steels and that too for friction stir welding.
■ The behaviour of weld zone ,heat affected zone and the base metal for tool steel like
H series and P series has not been properly studied with respect to the different
cooling media.
■ In the case of P series tool steels and H series tool steels, most of the work has
been centred around Laser beam Welding.
OBJECTIVES FOR MINOR PROJECT
■ Literature review
■ Selection of Materials.
■ Study of Tungsten Inert Gas Welding process and its effects on mechanical
properties of different steels.
■ Installation the GTAW setup and the market survey for the required materials..
■ Solid modelling of sample and simulations of the mechanical tests will be done on
ANSYS and Solidworks to obtain theoretical values.
OBJECTIVES FOR MAJOR PROJECT

■ Procurement of material and Cutting of samples with Wire EDM or Laser cutting
process.
■ The samples will be prepared for welding and then welded.
■ The mechanical properties will be determined using different tests like UTS test,
Rockwell hardness tests and Optical Microscopy.
■ A comparative summary of different properties will be made in accordance with the
results from the tests as well as from the simulation results.
Methodology
The completion of project will involve following steps:-
■ The different types of tool steel plate , filler material used in welding, tungsten
electrode of suitable dimension will be selected for welding.
■ Installation of Gas Tungsten Arc Welding setup .
■ The required samples will be cut from sheet by either laser cutting or wire EDM.The
samples will be prepared for welding and then welded.
■ The mechanical properties will be determined using different tests like Izod impact
test ,UTS test, Rockwell hardness test etc.( As per availability)
■ A comparative summary of different properties will be made in accordance with the
results.
 TIME FRAME
SEPTEMBER OCTOBER NOVEMBER DECEMBER JANUARY FEBRUARY
(2018) (2018) (2018) (2018) (2019) (2019)
LITERATURE
REVIEW
SELECTION OF
MATERIALS AND
OTHER
REQUIRED
SETUP
THEORETICAL
SIMULATION OF
THE
MECHANICAL
TESTS
WELDING OF
SAMPLES AND
ITS TESTING
STUDY AND
ANALYSIS OF
OBTAINED
RESULTS AND
CONCLUSION
PROGRESS
The progress in the minor project has been listed below
■ LITERATURE REVIEW
The literature review is being successfully conducted and the final selection of required
base papers is still under progress .
■ SELECTION OF MATERIAL AND PROCUREMENT
The required material for the experimentation has been selected and ordered as per the
requirement. The selected materials are:-
1. D2 steel – D2 is very wear resistant but not as tough as lower alloyed steels. The
mechanical properties of D2 are very sensitive to heat treatment. It is widely used
for the production of shear blades, planer blades and industrial cutting tools;
sometimes used for knife blades.
2. H13 Steel - DIN 1.2344 tool steel (also known as AISI H13 steel or just H13) is a tool
steel grade standardised for hot working. The main feature of this grade is the
combination of alloyed elements of chromium, molybdenum and vanadium, Cr-Mo-V,
which provides a high wear resistance to thermal shock. It is well known as for its great
strength, and heat resistance. It is heavily used for die casting in the cold heading field.
The presence of high vanadium in DIN 1.2344 can handle the abrasion at both low and
high temperatures. It always provides a uniform and high level of machinability. This tool
steel is mostly used for aluminium, magnesium and zinc die casting .

3. P20 Steel - P20 Mold Steel is a versatile, low-alloy tool steel that is characterized by
good toughness at moderate strength levels. The steel is commonly used for plastic
injection mold cavities and tooling and for die casting dies for zinc. P20 tool steels are
nitride or carburized. These steels are capable of being machined into complex and
large dies and molds. P20 steels are mostly used in the carburized condition. The
presence of chromium and nickel enhances the toughness and hardness of P20 steels.
■ INSTALLATION OF GTAW SETUP
The setup for Gas Tungsten arc welding has been installed at Automobile Lab, MAIT
Rohini. The machine that will be used has following specifications :
NAME TIG 250-A

INPUT POWER 380V

VOLTAGE
INPUT POWER TIG 6.2/MMA 7.7
CAPACITY
NO LOAD VOLTAGE 54
EFFICIENCY 85%
POWER FACTOR 0.93
TIG 250 –A Machine
WEIGHT 18.4 Kg
MEASUREMENT 505X218X355 mm
PROTETION CLASS F
DIAMETER OF ROD 1.6-4.0
ARC FORCE 0-60
ADJUSTMENT RANGE
■ SELECTION OF SHIELDING GAS
The mixture of Argon and Helium and that is typically used on thicker metals to get deeper weld
penetration. In most cases pure Argon will cover almost all welding needs. But the mixture of argon and
helium has the efficient weld penetration. Compared to the use of single gas, it provided 13 % more
weld penetration. Also both the gases are excellent for prevention of oxidation and minimizing carbon
precipitation.
■ OTHER PARAMETERS( FIXED)
1. Current range :- 90- 200 A
2. Tungsten Electrode Diameter ;- 2.4 mm
3. Thickness of work piece :- 10 mm
4. Torch angle: 30º
5. Polarity :- Straight
6. Gas Flow Rate :- 6L/min
7. Filler Material :- ER-70 S2
■ SELECTION OF COOLING MEDIA
1. Liquid Nitrogen (For Cryogenic Treatment)
2. Water
3. Mixture of Oil + Water
4. Air
■ DESIGN OF SPECIMEN( AS PER ASTM)
LENGTH :- 200 MM
WIDTH :- 10MM
THICKNESS :- 10 MM Weld Bead :-
5mm

■ INPUT PARAMETERS
1. LENGTH OF HAZ W.R.T WELD ZONE
2. TEMPRATURE ATTAINED DURING APPLICATION OF COOLING MEDIA
Simulation(Under progress)
■ Simulation for welded samples is under progress. The intial static study shows the
yield strength (820 N/MM2) for the designed sample of D2.
• Simulation for welded samples is under progress. The intial static study shows the
yield strength (742 MPa) for the designed sample of H 13.
REFERENCES
1. B. Das, B. Debbarma, R. N. Rai and S. C. Saha “Influence of process parameters on depth of
penetration of welded joint in mig welding process,” International journal of research in
engineering and technology 02 issue: 10-oct-2013 ISSN: 2321-7308.
2. D. M. Arya, V. Chaturvedi and J. Vimal “Parametric optimization of mig process parameters using
Taguchi and grey Taguchi analysis,” International journal of research in engineering & applied
sciences volume 3, issue 6 (june 2013) ISSN: 2249-3905
3. A. Hooda, A. Dhingra and S. Sharma “Optimization of mig welding process parameters to predict
maximum yield strength in AISI 1040,” International journal of mechanical engineering & robotic
research, vol. 1, no. 3, october 2012 ISSN 2278 – 0149 M Suhan and J Tusek (2001),
“Dependence of Melting Rate in MIG/ MAG Welding on the Type of Shielding Gas Used”, Journal of
Materials Processing Technology, Vol. 119, pp. 185-192.1.
4. S.C. Juang, Y.S. Tarng. ―Process parameter selection for optimizing the weld pool geometry in the
tungsten inert gas welding of stainless steel‖. Journal of Materials Processing Technology 122
(2002) 33–37S.C. Juang and Y.S. Tarng, “Process parameter selection for optimizing the weld pool
geometry in the tungsten inert gas welding of stainless steel,” Journal of Materials Processing
Technology 122 (2002) 33–37.
5. A. Ul-Hamid, H.M. Tawancy & N.M. Abbas, (2005) “Failure of weld joints between carbon steel pipe
and 304 stainless steel elbows”, Eng. Fail. Anal., Vol. 12, No. 2, pp 181–191.Ugur Esme, Melih
Bayramoglu, Yugut Kazancoglu, Sueda Ozgun Optimization of weld bead geometry in Tig welding
process using grey relation analysis and taguchi method. Original scientific article/Izvirni
znanstveni clanek -2009, P 143 149 .
7. W. Xu, M.F. Gittos. Material and structural behavior of MIG butt weld in 6005-T6
aluminium alloy extrusion under quasi-static and impact loading. TWI report No.
14054/1/04; (2004)
8. K.Y. Benyounis and A.G. Olabi, “Optimization of different welding processes using
statistical and numerical approaches – A reference guide,” Advances in Engineering
Software 39 (2008) 483–496.
9. Yusof Abdullah, Abdul Razak Daud, Roslinda Shamsudin, 2009. Mohd b. Harun. Flexural
Strength And Fracture Studies Of Al-Si/Sic Composites. International Journal of
Mechanical and Materials Engineering (IJMME). 4(2): 109-114.
10. R.E. Reed-Hill, R. Abbaschian, Physical Metallurgy Principles, 3rd ed., PWS Publishing
Company, Boston, 1992.
11. Wikipedia.com
12. American Welding Society - https://www.aws.org
13. American Society of Testing and Materials-https://www.astm.org/READINGLIBRARY/
14. NPTEL – youtube.com
THANK YOU