Experimental Investigation and Optimization of Welding Parameters for SAE 1020 and SS 303

In this study, the optimization of welding parameters for dissimilar joints of SAE 1020 and SS 303 using the Manual Metal Arc Welding (MMAW) process is investigated. The research aims to enhance the ultimate tensile strength (UTS) by employing the Taguchi method and Analysis of Variance (ANOVA) to analyze and optimize critical welding parameters: welding current, welding speed, root gap, and joint angle. Experiments were conducted following an L9 orthogonal array using Minitab 19 software, and a regression model was developed to predict UTS based on these parameters. The findings indicate that welding speed is the most significant factor influencing UTS, followed by root gap and welding current. Optimal parameter settings were identified, resulting in a maximum UTS value closely matching the predicted outcome with a minimal error margin of 2.59%. This study demonstrates the efficacy of statistical methods in optimizing welding conditions for achieving enhanced mechanical properties in dissimilar metal welding applications.