Modeling and Simulation of Welding Parameters in Tungsten Inert Gas Welding of Mild Steel

Tungsten Inert Gas welding (TIG) is the most widely used welding technique for industrial application. The execution of Gas Tungsten Arc Welding is complex in nature, therefore there is need to simplify this technique while trying to reduce cost of production and at the same time improve on quality of weld joint. Therefore, there is need to model the interaction of control welding parameters against desired quality parameters. This research paper aimed at creating a second degree response surface quadratic model having three cross product terms of current and gap-width (IG), welding speed and gapwidth (VG) and current and welding speed(IV) in order to visualize the interaction of current(I), welding speed(V) and geometric gap width of the welding joint(G). Comprehensive models were developed to show how control parameters interact with physical and geometric attributes optimally. The model was then simulated numerically in order to visualize the interaction of welding parameters against quality attributes such as heat affected zones, bead-width, and depth of penetration and tensile strength of the joint. Simulation models confirmed that mathematical models derived from second-degree response surface quadratic model fairly predicts optimal quality attributes of TIG weld joint in mild steel therefore simplifying the welding technique.