Parametric Optimization of TIG welding of Galvanized Steel with AA1050 using Taguchi Method

Tungsten Inert Gas welding (TIG) process is an important component in many industrial operations. The TIG welding parameters are the most important factors affecting the quality, productivity and cost of welding. Dissimilar welding of metal having different mechanical and physical properties is very difficult. The process tried here is weld brazing process. A filler rod is selected in such a way that it is compatible to both GI and Aluminium. On the aluminum side the filler rod will have proper fusion whereas on the Galvanized steel side the process will be a brazing operation in which a thin intermetallic layer is formed between the seam and the sheet. This paper presents the influence of welding parameters like welding current, welding speed and frequency on strength of Galvanized steel on AA1050 material during welding. A plan of experiments based on Taguchi technique has been used to acquire the data. An Orthogonal array, signal to noise (S/N) ratio and analysis of variance (ANOVA) are employed to investigate the welding characteristics of dissimilar joint and optimize the welding parameters. Finally the conformations tests have been carried out to compare the predicted values with the experimental values to confirm its effectiveness in the analysis of strength.