JMMCE  Vol.3 No.3 , May 2015
Reduction of Undercuts in Fillet Welded Joints Using Taguchi Optimization Method
Author(s) Joseph Achebo1*, Sule Salisu2
ABSTRACT
This project work focuses on the reduction of weld undercuts using the Taguchi method. The phenomenon of weld undercuts constitutes a major problem for the welding industry. When undercuts occur, and particularly when such cuts are deep, it has a negative impact on the weld as it lowers the integrity and quality of the weldment. Therefore, efforts are made globally to reduce the depth of such weld undercuts to the barest minimum. Several optimization methods have been adopted; however, in this study, the Taguchi method is applied. “The smaller the better components” of the Taguchi method is applied. From the results obtained from applying this Taguchi method, the optimum process parameters obtained are A2-B1-C2, which are a voltage of 20 V, a current of 180 A, and a welding speed of 130 mm/s, required to form an undercut of 0.03 mm. Whereas the existing process parameters used by the company are A1-B3-C, which make an undercut to a depth of 0.09 mm. It is concluded that the use of Taguchi method has been able to reduce the depth of undercut as shown in this study. A step-by-step approach is presented in the study.

Cite this paper
Achebo, J. and Salisu, S. (2015) Reduction of Undercuts in Fillet Welded Joints Using Taguchi Optimization Method. Journal of Minerals and Materials Characterization and Engineering, 3, 171-179. doi: 10.4236/jmmce.2015.33020.
References
[1]   Petershagen, H. (1990) The Influence of Undercut on the Fatigue Strength of Welds: A Literature Survey. Welding in the World, 28, 114-125.

[2]   Xu, W., Wu, C. and Zou, D. (2008) Predicting of Bead Undercut Defects in High Speed Gas Metal Arc Welding (GMAW). Frontiers of Materials Science China, 2, 402-408.
http://dx.doi.org/10.1007/s11706-008-0065-x

[3]   Garg, S., Kakkar, I., Pandey, A., Gupta, M. and Kishor, N. (2013) Effect of Different Coating Composition’s Rutile- Type Welding Electrodes on Undercut Defect in Manual Electric Arc Welding. International Journal of Mechanical Engineering and Research, 3, 381-388.

[4]   Servo-Robot (2015) Wiki-Scan Welding Inspection System.
http://wikiscan.servo-robot.com/wp-content/uploads/2012/07/wikiscanbrochurefinal.pdf

[5]   Spadea, J.R. and Frank, K.H. (2002) Fatigue Strength of Fillet-Welded Transverse Stiffeners with Undercuts. Center for Transportation Research, The University of Texas at Austin, Austin, Report No. FHWA/TX-05/0-4178-1.

[6]   Athreya, S. and Venkatesh, Y.D. (2012) Application of Taguchi Method for Optimization of Process Parameters in Improving the Surface Roughness of Lathe Facing Operation. International Refereed Journal of Engineering and Science (IRJES), 1, 13-19.

[7]   Achebo, J.I. (2012) Pipe Joint Strength Design and Service Life of a Pseudo Homogeneous All Weld Metal under Continuum Flow. In: Rivero, M.G. and Mansillo, L.M., Eds., Pipelines: Design, Applications and Safety, Chapter 9, Nova Science Publishers, New York, 225-257.

 
 
Top