Predicting Arc Welding Parameters for Enhanced Penetration Depth using Response Surface Methodology: A Multivariate Analysis of Current, Voltage, and Welding Speed Effects

Authors: Odio, O.B. And *Aliyegbenoma, C.O.

DOI Info: http://doi.org/10.5281/zenodo.18061431

ABSTRACT

This study addresses the critical challenge of optimizing Tungsten Inert Gas (TIG) welding parameters to achieve consistent penetration depth in AISI 1020 mild steel joints, a common requirement in industrial manufacturing where weld quality directly impacts structural integrity. The research aims to develop a predictive model that accurately correlates welding parameters (current, voltage, and speed) with penetration depth, eliminating the need for costly trial-and-error approaches in production environments. The methodology employed Response Surface Methodology (RSM) with a Central Composite Design (CCD) to investigate the effects of current (180 - 240A), voltage (18-24 V), and welding speed (16 - 22 mm/min) on penetration depth through conducting controlled welding experiments using ER70S-3 filler wire and argon shielding gas. Statistical analysis of the experimental data generated a quadratic regression model that quantifies the relationships between process parameters and penetration depth, validated through rigorous statistical measures including R-squared and lack-of-fit tests. Results demonstrated the model's exceptional predictive capability (R² = 0.9918), identifying current and voltage as dominant factors with significant quadratic effects, while welding speed showed secondary influence. The study concludes that the developed model provides manufacturers with a reliable tool for predicting penetration depth across various parameter combinations, offering substantial improvements in welding process control and quality assurance for mild steel fabrication.

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