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Reduction in Porosity in GMAW-P Welds of CP780 Galvanized Steel with ER70S-3 Electrode Using the Taguchi Methodology

  • Maleni García-Gómez
    ,
  • Francisco Fernando Curiel-López
    ,
  • ,
  • Víctor Hugo López-Morelos
    ,
  • Julio César Verduzco-Juárez
    ,
  • Carlos Adrián García-Ochoa
  • Universidad Michoacana de San Nicolas de Hidalgo
    ,
  • University of Texas Rio Grande Valley
Research Output:
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Article
Peer-review

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4
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0.44
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6
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49
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Abstract

In this study, the theoretical welding parameters influencing porosity formation were examined with the aim of reducing or minimizing porosity levels. An experimental design was implemented using the Taguchi methodology for data analysis, resulting in an L9 orthogonal array matrix of experiments. The welding variables considered in the orthogonal array were peak current, peak time, and frequency. Nine lap welds were performed on CP780 steel using the gas metal arc welding process with pulsed arc (GMAW-P), employing an ER70S-3 electrode as filler metal. The percentage of porosity was determined as a response variable, and the actual heat input was treated as a covariable, thereby identifying the welding parameters with the predicted values. Three repetitions were conducted with the optimal welding parameters to validate the Taguchi prediction. The quality of the welds was assessed through radiographic inspection, and metallographic preparation was performed, revealing the microstructure with 5% Nital for 12 s. The samples were analyzed using an optical microscope, and images were obtained with the collage technique. The results showed that the welding parameters predicted by the Taguchi statistics were favorable for all three predicted welded joints. The maximum percentage of porosity obtained was 19%, which was reduced to 1% using the Taguchi methodology, demonstrating the effectiveness of this statistical tool for process optimization. It was observed that for heat input values of 230 to 250 J/mm, the presence of porosities is dramatically reduced, finding a very small window that allows the gases generated by the burning of zinc to be expelled to the surface.

Publication Information

Output type

Research Output:
Contribution to journal
Article
Peer-review

Original language

English

Article number

857

Journal (Volume, Issue Number)

Metals (Volume 14, Issue 8)

Publication milestones

  • Published - 08/2024

Publication status

Published - 08/2024

Publication IDs

  • Scopus: 85202634402

Funding Details

The authors thank Metalsa for providing materials, the support of the Universidad de Monterrey and Coordinaci\u00F3n de la Investigaci\u00F3n Cient\u00EDfica (CIC) of the Universidad Michoacana de San Nicolas de Hidalgo, and CONAHCYT for providing a scholarship to M.G.-G. during his Ph.D.\u2019s degree studies.
FundersFunding numbers
CIC
-UDEM-
Conahcyt
-
UMSNH
-