Predicting the 2F-T Fillet weld bead geometry and its welding parameters for GMA Welding

Abstract

This paper presents the prediction of T-Fillet weld bead geometry and its welding parameters for horizontal position. The weld bead is welded by GMAW with CO2 shielding gas on T-joint of carbon steel. The 125 samples are welded at a wide range of current, voltage and welding speed. The macro-etched samples present the actual data of weld bead geometry for the respective welding parameters. The results are plotted in graphs for analysis. From the charts, empirical formulae are developed and their trend-lines such as average bead size, bead penetration, actual throat and bead width are obtained. With these formulae and trend-lines, one can predict the size of 2F-T Fillet weld bead geometry for GMA welding parameter where welding is allowable. Conversely for any good weld profile (leg-size), required GMA welding parameters can be predicted. The validated results are confirmed by the Mean Absolute Deviation (MAD) which the error is less 1.0mm. The confirmation test sample is tested through the Welding Procedure and Specification (WPS) accordance with AWS D1.1 Standard. The weld predictor and calculator developed from this research may abridge the task of welding design and production.