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Application of Two-Level Half Factorial Design Technique for Developing Mathematical Models of Bead Penetration and Bead Reinforcement in SAW Process

Vijay Kumar Panwar, Deepak Kumar Choudhary

In the present work two level half factorial design techniques is used to develop the mathematical models for bead geometry parameters like weld bead penetration and reinforcement height. The practical were performed on automatic SAW machine by making bead-on plate of 12mm thick carbon steel plates. The process variables were taken as welding current, arc voltage, welding speed and nozzle to plate distance. Main and interaction effects of process variables on the responses were analyzed with the help of 2D and 3D graphs. The models developed have been checked for their adequacy and significance by using F-test and t-test, respectively with the help of Design Expert software. Result represents that bead penetration and reinforcement increases with the increase in welding current while decreases with the increase in arc voltage and nozzle to plate distance. Nozzle to plate distance has no significant effect on both bead penetration and reinforcement.