Abstract
In submerged arc welding (SAW), selecting appropriate values for process
variables is essential in order to control heat-affected zone (HAZ)
dimensions and get the required bead size and quality. Also, conditions
must be selected that will ensure a predictable and reproducible
weld bead, which is critical for obtaining high quality. In this
investigation, mathematical models were developed to study the effects
of process variables and heat input on various metallurgical aspects,
namely, the widths of the HAZ, weld interface, and grain growth and
grain refinement regions of the HAZ. The color metallography technique
and response surface methodology were also used. Direct and interaction
effects of the process variables and heat input on the characteristics
of the HAZ were presented in graphical forms. The study revealed:
1) heat input and wire feed rate have a positive effect, but welding
speed has a negative effect on all HAZ characteristics; 2) width
of grain growth and grain refinement zones increased and weld interface
decreased with an increase in arc voltage; and 3) width of HAZ is
maximum (about 2.2 mm) when wire-feed rate and welding speed are
at their minimum limits.
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