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"Optimization of Shielded Metal Arc Welding (SMAW) process for mild steel"

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TRANSACTIONS
2019
PART B

Technical Papers
Annual Sessions of IESL, pp. [841 - 847], 2019 iesl/pub/guide
© The Institution of Engineers, Sri Lanka

Optimization of Shielded Metal Arc Welding

(SMAW) process for mild steel
L. S. Sisira K Weerasekralage, M. S. A. Karunaratne, S. D. Pathirana

Abstract: Shielded Metal Arc Welding (SMAW) or the conventional arc welding process is
particularly dominant in structural joints, pressure vessels and in maintenance and repair work. This
process is widely used in many industrial applications due to its versatility, simplicity and indoor and
outdoor applicability. A certain level of operational skills is needed in performing the SMAW process
in order to obtain a quality weldment. Further, input process parameters such as current, voltage, arc
gap, welding speed, electrode orientation, etc. play a vital role in the quality of the weldment.
This research especially addresses and simulates mild steel in arc welding, covering industrial
applications including small scale industries. The study investigates the influence of different input
process parameters on weld quality through mechanical tests and verified through microstructural
examinations. Further, authors wish to identify the optimized process variables in obtaining quality
weldment at minimum cost for real industrial applications. For the study, thirty-six number of welded
samples of mild steel were selected based on a full factorial array, Taguchi’s orthogonal array, welding
standards, power source specifications and deviations based on a trial experiment. According to the
planned experimental procedure, three types of mechanical tests (hardness, toughness and tensile)
followed by the microstructural tests were carried out. Results of the investigation revealed that the
12th, 9th and 11th sample sets with corresponding input parameters had produced the best quality
weldments. As their joint characteristics, tensile properties are better with poor impact toughness
compared to the base metal
Keywords: Arc Welding, SMAW, Optimization, Mechanical tests, Microstructure

1. Introduction (SMAW) process is chosen due to its simplicity

as few process-attributes such as workpiece,
It is the objective of this study to identify the welder, power source and electrode make the
optimum welding parameters for the manual set up complete. It is an effective and low-cost
SMAW process in order to facilitate the process for producing quality products [8].
industrial applications for better quality Application of SMAW or Manual Metal Arc
weldments. Especially this research addresses Welding (MMAW) is gradually replaced in the
and simulates commonly mild steel in arc global context with the introduction of new
welding, covering industrial applications processes while it is very important for
including small scale industries. An developing countries with low-cost
investigation was carried out to establish the infrastructure, simplicity and availability of
concept by selecting welding current, voltage human capital [7]. The shielded metal arc
and groove angle as input welding parameters welding is most widely used in small scale
[1][2]. As per SMAW process optimization, industries, because of its low cost, simplicity,
hardness, toughness/impact strength and flexibility and portability [10]. Further, manual
tensile strength were determined and analyzed welding still occupies a leading position in
experimentally in customizing industrial domestic, maintenance, fabrication and offshore
application with the intended purpose applications [3].
[3][[4][[5]. Further, it is important and possible Special advantages of Shielded Metal Arc
to improve process optimization continuously Welding (SMAW) process are the improved
with different software developed with data microstructure at the welded joint by varying
acquisition systems (DAC for big data) in L. S. Sisira K. Weerasekaralage
formulating optimized algorithms [6][7]. BTech(Mech Eng)(OUSL), MSc Eng (Peradeniya)
Mechanical Engineer/Lecturer,Faculty of Eng, SLIIT.
The selection of an arc welding process is
complex with respect to the workpiece, Dr. M. S. A. Karunaratne
application, simplicity, infrastructure, cost, [Link]. Eng. (Moratuwa), PhD (Cambridge)
Head Dept of Material Eng, Faculty of Eng, SLIIT
expected quality, etc. Therefore, a particular
welding application is performed with the Eng.(Prof.) [Link]
interaction of many factors and attributes as BScEng (Peradeniya), MSc, PhD, MASME, MIEEE,
shown in Figure 1. In this regard, the CEng. MIET & FIE(SL), Professor of Production
Engineering, University of Peradeniya.
arrangement of Shielded Metal Arc Welding

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Figure 1 Attributes of arc base welding
processes
effects of different factors on weld pool
chemical coating formulation, availability of
geometry [19][23]. SMAW Process utilizes a
electrodes for almost all steels [Welding
constant current type of power sources and
Handbook, 1991], proper weld zone protection
different electrodes with flux coatings having
without additional equipment and possible to
different arc characteristics [24][25][26].
produce thin electrodes in diameter (up to
1mm) [8]. SMAW is carried out best by human
skill and practice and assessed by inspection
2. Methodology
and/or testing of the weld [11]. Methods based
on the measurement of input welding The experiment was designed with an
parameters (such as current, voltage, groove alternating current power source (EX6-250 AC
angle, electrode orientation, etc.) could be Arc Welder-90A/23.6V-250A/30A). Samples of
applied in assessing welding skill and weld mild steel, ASME SA216WCC (width 24 mm ×
quality. Further, the skill of a welder largely thickness 5 mm) were welded manually at 1G
depends on the ability of the welder in position with Ø 2.5 mm diameter AWS-E6013
maintaining a constant arc gap which, in turn, electrodes (low cost mostly available brand of
results in steady-state arc voltage [1][3][12][13]. welding rods). Especially these welding rods
Highly skilled human welder’s responses are are used to address and simulate common
captured in developing models/simulations industrial usage covering mild-steel SMAW as
and also in developing automated welding mostly practiced by small scale industries too.
systems [9][14][15]. Hazards could occur during
the SMAW process if proper safety precautions Table 1 Composition of base metal and
are not taken. To minimize the risk of electric electrode specifications
shock, health hazards and environmental
protection, welders should wear personal Material Base Metal
protective equipment (PPE) and process control SA216 WCC
Grade
devices during welding and allied processes
Mn 0.44
[15].
Si 0.18
Welding process optimization through
quantitative analysis is profound and far- Cr 0.14
Composition (%)

reaching significance in obtaining quality Mo < 0.02

weldment at a low cost. Scientific analysis of V < 0.02
the welding process could be useful and done Ni 0.08
through a multidisciplinary approach Cu 0.17
combining electromagnetic effects, heat P 0.022
transfer, fluid flow and solidification. Weld C 0.25
pool geometry is closely related to weld quality S 0.026
[16][17][18][19][20][21][22]. AWS E6013, 2.5 mm diameter
Experimental research on SMAW is complex Electrode Rutile, AC/DC, all positions
and it is required to establish a model of heat UTS-414 MPa
and mass transfer to investigate the

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Table 2 Experimental Metrix with results
Output Parameters for Weld Quality
Specimens Input Parameters Mechanical Testing
Visual
Analysis

Hardness (HRC) ‘Avg’

Input Parameter

Input Parameter

Penetration (%)

Toughness (J)
Weld Quality
Sample Code

Grove Angle
Current (A)

(Rank 1-10)
Voltage (V)
Cluster No.
Tensile
Set No.

‘ Avg’
Strength Heat Affected

Weld-pool
(MPa) Zone (8mm from
‘Avg’ center)

Left Right
1 I11H, I11T 76 26 40 30 2 52 7 93 93 89
1 2 I12H, I12T 73 27 50 32 3 107 21 89 99 88
3 I13H, I13T 76 26 60 36 3 172 22 88 94 84
4 I21H, I21T 87 25 40 60 3 189 17 99 98 87
2 5 I22H, I22T 87 25 50 69 4 246 20 93 99 93
6 I23H, I23T 88 27 60 73 5 261 39 95 97 98
7 I31H, I31T 105 28 40 90 9 268 14 99 97 102
3 8 I32H, I32T 103 28 50 100 10 298 22 98 96 96
9 I33H, I33T 103 27 60 100 10 306 39 97 95 95
10 I41H, I41T 119 29 40 100 10 326 15 98 97 98
4 11 I42H, I42T 116 29 50 100 10 346 24 97 95 101
12 I43H, I43T 123 27 60 100 10 355 41 102 102 98
B B Base Metal 513 117 99

Chemical composition and specifications of Charpy impact tests were carried out for all
welding samples and electrode specifications welded samples using JB-300 impact testing
are given in Table 1. The process of manual machine for specimen preparation, V-notch of
shielded metal arc welding (SMAW) was the same size is machined at the center line of
performed with different combinations of input the weld bead and along the welding direction
parameters for 12 sets of samples (six sets for using 450 V- notch cutting machine. All the
tensile tests and six for hardness and toughness results are shown in Table 2.
tests in different dimensions) comprise of 36
workpieces for better accuracy (three specimens 3. Results and Discussion
for each trail).
The experiment was designed based on First and second data sets (Cluster No.1 and
combinations of input parameters considering No.2) are not considered for the analysis due to
welding standards, full factorial array,
poor weld quality with insufficient penetration,
Taguchi’s orthogonal arrays, power source
porosity and inconsistencies observed in the
specifications and deviations required for the
weld parameters (i.e. poor weldments).
investigation (Table 2). Specimen preparation
was performed with three V-groove joints (40⁰, Experimental values of hardness, toughness or
500 and 600) ensuring the ISO 9692 standard [27]. impact resistance and ultimate tensile stress
The length of the welded area was fixed were obtained (Table 2) and analyzed as given
throughout the process assuming constant arc below.
gap, torch orientation and welding speed of
manual welding [3][28][29]. 3.1 Hardness properties
All the mechanical tests were performed at Average Rockwell hardness values obtained
room temperature (300K) and comply with under selected combinations of weld
ASTM standards. Rockwell hardness test was parameters are plotted in Figure 2 using
performed using HR-150A hardness tester with experimental results in Table 2. Higher
diamond indenter at HRC scale (major load hardness is observed in the weld-zone in all
150kg, minor load 10 kg and diamond 120⁰, 0.2
three clusters for all specimens. This can be
tip radius).
ascribed possibly to the microstructure
Tensile tests were carried out using a universal
testing machine (UTM 1000E) with the electro- resulting from the higher cooling rates
hydraulic servo control unit. Maximum force experienced by the weld-zones [30][31][32][33].
reading until the fracture was taken and saved
for all specimens and maximum stress was
calculated.

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3.2 Toughness properties The experiment revealed that the highest
Toughness or impact resistance of the toughness is 41 J (12thspecimen in cluster No 4)
weldments of SMAW is comparatively low whereas the toughness of the base metal is 117
compared to those generally obtained using J. Accordingly, the highest toughness or impact
Gas Metal Arc Welding (GMAW), Gas strength is 35% that of the base metal during
Tungsten Arc Welding (GTAW) and SMAW process. Furthermore, impact
Submerged Arc Welding (SAW), and Friction toughness severely decreased with the
Stir Welding (FSW). Toughness results are decreased groove angle (specimen set 11th& 10th
shown in Table 2 and plotted in Figure 3 and specimen set 8th & 7th). Low values of
[34][35]. toughness could be due to the formation of fine
grain structure and/or martensite. Presence of
grain boundary ferrite which provides crack
propagation paths and cracks enhance by high
cooling rates [31][32][33][34][35]. Determination
of the fracture mechanisms responsible for
impact failure, however, is beyond the scope of
this work.

3.3 Tensile properties

Tensile properties of welded samples of SMAW
are better compared with impact strength. The
experiment result shows ultimate tensile
strength is 355 MPa for welded joint of 12th
Figure 2 Hardness of weldments specimen set and 513 MPa for base metal which
shows 70% of UTS recovered after arc welding
compared with the base metal. Tensile
properties of welded samples are plotted in
Figure 4 which are based on the experimental
results shown in Table 3.
The best values of ultimate tensile strength in
the weld zone are obtained in the 12th&11th sets
of cluster No.4 and 9th & 8th sets of cluster No.3
of specimens (Table 3). Further, higher the
groove angle (600) in 12th & 9th sets of cluster
No.4 gives the higher tensile strength (Figure
4). Therefore, tensile strength is influenced by
the groove angle (“V” groove) of joint
preparation. This can be due to the result of
better bonding with higher heat input, mass
transfer and faster cooling [31][32][33][36].
Figure 3 Toughness of weldments
3.4 Microstructure and Metallographic
characterization
The metallographic phase structures of samples
were compared against those predicted by the
Iron-Carbon diagram. Phase structures
obtained for selected specimens are shown in
Table 3, which reveals that the microstructures
(Figure 5) are almost identical. The weld-zone
microstructure is mainly dependent on the heat
input and cooling rate, and contains a
combination of grain boundary ferrite, side-
plate ferrite, acicular ferrite, bainite and
martensite. These features are fairly consistent
with the microstructures obtained with
Figure 4 UTS of weldments continuous cooling of low carbon steel.

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Table 3 Metallurgical analysis of specimens mm thick mild steel flat members. But it could
be varied and to be investigated with the higher

Cluster No.
Parameter HAZ 1cm Weld HAZ 1cm Base length of welding for both weld-zone and heat-
Left zone Right Metal affected zones (HAZ).

Ferrite + Ferrite + Ferrite + Best quality of weldment with highest ultimate

Coarse tensile stress (UTS) (with brittle property) is
3 Pearlite Pearlite Pearlite
Pearlite obtained when the current, voltage and groove
(5%) (5%) (0.2%)
angles are 123A, 27V and 600 respectively with
Ferrite + Very Ferrite + Ferrite +
the result of mechanical tests (Table 2, Table 3,
4 Pearlite Fine Pearlite Pearlite Table 4 and Figure 4).
(5%) Pearlite (5%) (0.2%)

At the start of cooling of the weld, grain

boundary ferrite formation is initiated and
subsequently, diffusion rates decrease with
further cooling to low temperatures. Acicular
ferrite nucleates and grows with intragranular
inclusions [32]. On the other hand, higher heat
input enhances diffusion and promotes grain
boundary ferrite. However, under higher
cooling rates, the nucleation rate is faster and,
hence, transformations begin earlier. Therefore, Figure 5 Microstructure of specimens
comparatively, the samples which have
experienced a low-temperature regime show a In addition, higher UTS can be achieved with
mixed microstructure comprising acicular cluster No.3 and No.4 when welding current is
ferrite and lath-martensite [31], [32, [33][37]. 104 A and 119 A (mean value for current setting
for the AC power source) respectively. Tensile
Table 4 Mechanical properties of best samples strength increases with increased groove angle
of weld pool (Tables 2 & 4) It is metallographically verified
Sam Input Properties of Weld pool (Table 3 and Figure 5).
ple Combination UTS Toughne Hard
Set Current/ Rank ss ness
No. Voltage Strength Rank Toughness levels of SMAW against weld
“V” groove angle % Rank % % geometry is very important in assuring the
Base Metal 100 100 100
reliability of the welded joint. The work found
8 103/28/50 58 19 97
9 103/27/60 64 33 96 that toughness or impact resistance of the
11 116/29/50 67 21 102 weldments of manual SMAW is comparatively
12 123/27/60 69 35 100 very low as shown in Tables 2 and 4. According
to the results, the highest toughness is 35% that
4. Conclusions of the base metal during the SMAW process.
Furthermore, it is revealed that impact
The following conclusions could be derived toughness severely decreased with the
and summarized for SMAW welding of 5mm decreased groove angle.
thickness mild steel plates/flat bars with 2.5 It is expected to continue this area of research in
mm diameter E6013 electrodes with general optimizing the SMAW process with more input
joint preparation at the lowest cost suitable for parameters, output/quality parameters with
the actual industrial environment. metallographic characterization.

High hardness values are obtained for all Acknowledgment

specimens of all three clusters (Table 2) due to The authors gratefully acknowledge the faculty
higher cooling rates at the surface. Therefore, it of engineering and graduate studies & research
is observed that hardness is not much affected of Sri Lanka Institute of Information
by the SMAW process for 24 mm width and 5 Technology (SLIIT), Janith K. Wijesinghe, P. K.

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