Direct Effect of Plasma Transferred Arc Welding Process Parameters

on Bead Geometry of Hardfaced Gate Valve

S.M.Sivagami
1
Dr.N.Murugan
2
K.Punitharani
3
1. Research Scholar, Dept. of Mech. Engg .,CIT, Coimbatore, Tamilnadu, India
2. Professor, Dept. of Mech. Engg., CIT, Coimbatore, Tamilnadu, India.
3. Lecture, Dept. of Mech. Engg. PSG Tech, Coimbatore, Tamilnadu, India.
Corresponding mail Id : smshivagami@gmail.com
ABSTRACT
Weld Hardfacing is an effective method for modifying the surface properties of components
such as wear, corrosion and heat resistance under high pressure and high temperature conditions.
The quality of hardfaced components depends on the weld bead geometry which greatly influenced
by welding process parameters. Therefore, it is essential to develop mathematical models for the
selection of appropriate welding process parameters that can predict the desired weld bead
geometry. This paper mainly focused on the development of mathematical models using five factor,
five level factorial technique to predict weld bead geometry in 50 mm thick hardfaced Gate Valve.
The developed models were checked for their adequacy. The direct effect of welding process
parameters on the weld bead geometry are presented in graphical form, which helps in selecting
desired process parameters to obtain the high quality welds.
Key words: Hardfacing, PTAW, Process parameters, Bead geometry, Central composite
rotatable design.
1.0 INTRODUCTION
Weld hardfacing is a process of
depositing a powder material on the surface of
substrate to increase its wear abrasion, impact,
corrosion and heat resistance [1]. Stellite-6 (Co-
Cr- A) is generally used hardfacing alloy, having
excellent resistance to many forms of wear and
corrosion [2 - 4] over a wide range of
temperature, which results in its wide use as a
valve surfacing material. Moreover, this alloy is
ideally suited to a variety of hardfacing
processes.

The weld hardfacing are generally done
by traditional welding processes such as Oxyfuel
gas welding (OFW), Gas Tungsten Arc welding
(GTAW), Manual Metal Arc Welding
(MMAW), Gas Metal Arc Welding (GMAW)
and Submerged Arc Welding (SAW) [5].
Compared to these processes, PTA surfacing
provides a higher deposition rate, relatively
lower dilution and also it permits precise control
IJAEA, Volume 1, Issue 6, pp.44-52 (2008)
Fragrance 44

of important welding process parameters to
obtain the desired weld characteristics [6].
Weld characteristics which include bead
geometry, thermal cracks, undercutting,
penetration and Heat Affected Zone (HAZ)
profiles are important criteria in determining the
weld quality of any metal [7]. These
characteristics are generally influenced by
PTAW process parameters such as welding
current, welding speed, powder feed rate, plasma
gas flow rate, powder gas flow rate, oscillation
frequency and nozzle to plate distance [8].
Therefore, it is essential to study the direct effect
of process parameters with the help of
mathematical models for obtaining desired weld
quality. The main objectives of this paper were
to develop the mathematical models explaining
the direct effect of PTAW process parameters on
bead geometry and % dilution of hardfaced Gate
Valve. The experiments were based on the
central composite rotatable design matrix.
Regression analysis was used to develop the
models and the analysis of variance was used to
test its adequacy.

2.0 EXPERIMENTAL WORK
The 50 mm thick low alloy steel (AISI
4140) Gate Valve having outer , inner diameter
and groove depth of 69.8 mm ,42 mm and 2 mm
on both sides. Table 1 shows the chemical
composition of the valve body and surfacing
material (% weight). The valves were preheated
at a temperature of 450 C for 1 hour before
deposition of stellite-6 alloy in order to avoid
moisture, cold crack, entrapped hydrogen and to
minimize the residual stress induced [9, 10]. The
deposition was done on both sides of the Gate
Valve by PTAW process with different level of
welding process parameters. After hardfacing,
the Gate Valves were stress relieved immediately
at a temperature of 630 C for 2 hours. The
typical hardfaced Gate valve is shown in Fig. 1.


Fig. 1 Typical Hardfaced Gate Valve
These hardfaced Gate Valves were
sectioned transversely using wire cut EDM to
examine the weld bead geometry on circular
cross section. The macro photograph of the real
weld bead is shown in Fig.2.

Table 1 Chemical Composition of AISI 4140 and
Stellite -6 (% Weight)
ELEMENTS AISI 4140 STELLITE - 6
C 0.37 1.08
Si 0.15 1.09
Mn 0.60 1.00
Cr 0.80 28.75
Mo 0.15 -
Co - Bal
Ni 0.50 2.5
P 0.04 -
S 0.04 -
V 0.10 -
W - 4.37
Fe - 2.50


Fig.2 Real Weld Bead

The cross section of an ideal weld bead
showing the bead geometry is given in fig.3.



Fig.3 Ideal Weld Bead Geometry
Area A: Added metal P Penetration
R
P

A
B
W
IJAEA, Volume 1, Issue 6, pp.44-52 (2008)
Fragrance 45

Area B: Base metal R Reinforcement
W Width % Dilution =[B/
(A+B)] x 100

3. 0 PLAN OF INVESTIGATION
The work was planned to be carried out
in the following steps [11 -13].
(a) Identification of important process
parameters.
(b) Finding the limits of the identified
process parameters.
(c) Developing the design matrix.
(d) Conducting the experiments as per
the design matrix.
(e) Recording the responses.
(f) Developing the mathematical
model
(g) Checking the adequacy of the
model developed.
(h) Presenting the direct effects of
process parameters in graphical
form and analyzing the results.

3.1 Identification of Important Process
Parameters
The independently controllable process
parameters identified to carry out the
experimental work were welding current (I),
welding speed (S), powder feed rate (F), plasma
gas flow rate (G) and oscillation frequency (H).
The remaining parameters were maintained at
constant for all the trials.

3.2 Finding the Limits of the Identified
Process Parameters
The upper and lower limits of the
process parameters were decided by conducting
trial runs to obtain the absence of visible defects
if any. The upper and lower limit of a factor was
coded as +2 and 2 and the coded values for
intermediate ranges being calculated from the
relationship

X
i
= 2[2X(X
max
+X
min
)]/((X
max
X
min
)
(1)

Where X
i
is the required coded value of a
variable X and X is any value of variable from
X
max
to X
min
. X
min
and X
max
are the lower and
upper level of the variable. The selected levels of
the process parameters with their units and
notations are given in Table 2.


Table 2 Welding Process Parameters and their
Levels
Parameter Unit Factor Levels
-2 -1 0 1 2
Welding current Amps 150 160 170 180 190
Welding speed mm/min 150 175 200 225 250
Powder feed rate grams/min 20 25 30 35 40
Plasma gas flow rate LPM 2.5 3.0 3.5 4.0 4.5
Oscillation frequency cycles/min 35 37 39 41 43

3.3 Developing the Design Matrix
The selected design matrix shown in
table 3 is a central composite rotatable factorial
design consisting of 32 sets of coded conditions
comprising 2
5-1
(=16) factorial design plus 6
centre points and 10 star points. Therefore, the
32 experimental runs are used to estimate the
direct effect of welding process parameters on
the weld bead geometry and % dilution.

3.4 Conducting the Experiments as per Design
Matrix
The experiments were conducted at
Bharat Heavy Electricals Limited, Tiruchirapalli,
with the help of following experimental setup.

Machine: Stellite Hettiger Plasma Transferred
Arc Welding, Germany.
Electrode: 2% thoria tungsten electrode.
Electrode diameter: 4 mm
Electrode Angle: 45
Shielding gas: 99.995% commercial Argon.

The total of 32 Gate Valves were
hardfaced as per design matrix.








IJAEA, Volume 1, Issue 6, pp.44-52 (2008)
Fragrance
46

Table 3 Design Matrix and Observed Values of Weld Quality Parameters
Trial
No


Design Matrix Response
I S F G H P (mm) R (mm) W (mm)

D (%)
1 -1 -1 -1 -1 +1 2.14 4.54 17.86 25.56
2 +1 -1 -1 -1 -1 2.99 4.08 19.54 40.23
3 -1 +1 -1 -1 -1 2.79 2.73 15.50 26.55
4 +1 +1 -1 -1 +1 2.57 2.60 15.79 32.28
5 -1 -1 +1 -1 -1 1.34 4.19 18.46 20.3
6 +1 -1 +1 -1 +1 2.11 4.98 17.46 26.01
7 -1 +1 +1 -1 +1 1.07 5.08 15.50 26.55
8 +1 +1 +1 -1 -1 1.38 5.06 15.87 26.64
9 -1 -1 -1 +1 -1 2.52 4.97 20.01 45.02
10 +1 -1 -1 +1 +1 5.92 2.72 18.55 48.11
11 -1 +1 -1 +1 +1 2.32 3.60 17.62 37.57
12 +1 +1 -1 +1 -1 3.58 2.90 17.26 48.86
13 -1 -1 +1 +1 +1 1.72 5.32 18.62 16.36
14 +1 -1 +1 +1 -1 4.14 3.21 20.45 45.53
15 -1 +1 +1 +1 -1 0.96 3.11 17.05 17.99
16 +1 +1 +1 +1 +1 1.67 3.31 17.78 21.89
17 -2 0 0 0 0 1.79 4.76 17.26 25.22
18 +2 0 0 0 0 4.65 3.07 19.72 46.34
19 0 -2 0 0 0 4.37 4.74 20.19 45.83
20 0 +2 0 0 0 1.72 3.05 15.49 25.68
21 0 0 -2 0 0 4.63 3.01 17.68 52.49
22 0 0 +2 0 0 1.27 4.32 18.76 20.20
23 0 0 0 -2 0 2.01 4.01 16.69 28.26
24 0 0 0 +2 0 3.85 3.33 19.64 41.53
25 0 0 0 0 -2 2.80 3.40 16.77 42.46
26 0 0 0 0 +2 3.10 3.80 16.79 33.97
27 0 0 0 0 0 3.05 3.95 18.21 35.14
28 0 0 0 0 0 3.00 3.90 17.74 34.79
29 0 0 0 0 0 2.99 3.97 18.21 35.14
30 0 0 0 0 0 3.07 3.86 18.21 35.35
31 0 0 0 0 0 3.02 3.90 17.59 34.89
32 0 0 0 0 0 3.00 3.91 17.59 35.00
IJAEA, Volume 1, Issue 6, pp.44-52 (2008)
Fragrance
47

3.5 Recording the Responses
The hardfaced Gate Valves were cut
transversely using wire cut EDM with 0.1 mm
diameter brass wire, these specimens then being
prepared by the usual metallurgical polishing
methods and etched with 2% Nital solution .The
profiles of the weld bead were traced using
optical profile projector and the bead dimensions
viz. bead width, depth of penetration and height
of reinforcement were measured. With the help
of digital planimeter, the area of penetration and
area of reinforcement were measured on top and
bottom surfaces and the percentage of dilution
was calculated. The observed values of W, P, R
and % D are given in Table 3.

3.6 Developing the Mathematical Models
In order to evaluate the effect of process
parameters on the bead geometry, the
mathematical models have been developed
between process parameters and bead geometry.
In general, the response function can be
expressed as [14]

Y =f (I, S, F, G, H)
(2)

Where Y is the measured response (Penetration,
Reinforcement, Width, %Dilution)
I is welding current, Amps
S is welding speed, mm/min
F is powder feed rate, grams/min
G is plasma gas flow rate, LPM
H is oscillation frequency, cycles/min

The second order response surface
model for the five parameters could be expressed
as

Y =b
0
+b
1
I +b
2
S +b
3
F +b
4
G +b
5
H +b
12
IS +
b
13
IF +b
14
IG +b
15
IH +b
23
SF +b
24
SG +
b
25
SH +b
34
FG +b
35
FH +b
45
GH +b
11
I
2
+
b
22
S
2
+ b
33
F
2
+ b
44
G
2
+ b
55
H
2

(3)

Where b
0
Free term coefficients, b
1,
b
2
, b
3
, b
4

and b
5
Linear coefficients, b
11
, b
22
, b
33
, b
44
and
b
55
Quadratic coefficients and b
12
, b
13
, b
14
, b
15
,
b
23
, b
24
, b
25
, b
34
, b
35
and b
45
Interaction
coefficients.

The final mathematical models with
parameters in coded form are given below.

P =2.738 +0.635I - 0.493S - 0.715F +0.42G -
0.336IS +0.379IG - 0.313SG
(4)

R =3.858 - 0.336I - 0.376S +0.364F - 0.229G +
0.112H +0.211IS +0.151IF - 0.314IG
0.325IH +0.209SF - 0.286FG +0.272FH
(5)

W =18.057 +0.291I - 1.166S +0.719G -
0.205H
- 0.328H
2
+0.171SG +0.436SH
(6)

% D =33.68 +4.828 I - 2.88S - 6.978F +3.489G
- 2.24H - 1.977IS +1.328IG - 1.822IH
1.789SG +2.081SH - 3.292FG -1.884GH
(7)

3.7 Checking the Adequacy of the Model
Developed
The adequacy of the developed models
was tested by the Analysis of Variance
(ANOVA) technique. As per this technique, the
calculated values of F-ratios were larger than the
tabulated values at 95% confidence level, as
shown in table 4. Hence, the models are said to
be adequate [15].

3.8 Testing Coefficients for Significance
The significance of coefficients was
tested by observing the coefficients of full
models and reduced models. The coefficients of
R
2
and adjusted R
2
for full models and reduced
models are presented in Table 4 .These values
indicate that reduced models are better than the
full models because the adjusted R
2
values are
improved for reduced models. Finally the
validity of developed models was again tested by
drawing scatter diagram. The observed and
predicted values of the responses are scattered
close to 45 line, indicating an almost perfect fit
of the developed empirical model, as shown in
fig. 4 to fig.7.

IJAEA, Volume 1, Issue 6, pp.44-52 (2008)
Fragrance 48

0
2
4
6
0 2 4 6
P
r
e
d
i
c
t
e
d

v
a
l
u
e
s

o
f
P
e
n
e
t
r
a
t
i
o
n

(
m
m
)
Observed values of Penetration (mm)


Fig. 4 Scatter Diagram for Penetration Model


Table 4 Analysis of Variance for Testing Adequacy of the Models

Bead Geometry Full Model Reduced Model
F
ratio
P-
value
R-sq Adj.
R-sq
F
ratio
P-
value
R-sq Adj.
R-sq
Penetration 10.64 0.00 0.95 0.86 29.01 0.00 0.90 0.86
Reinforcement 29.79 0.00 0.98 0.95 49.68 0.00 0.97 0.95
Bead Width 10.22 0.00 0.95 0.86 42.86 0.00 0.93 0.90
% Dilution 8.92 0.00 0.94 0.84 19.35 0.00 0.92 0.88

Tabulated Values of F: P (7, 24) =2.42
R (12, 19) =2.31
W (7, 24) =2.42
D (12, 19) =2.31

2
3
4
5
6
2 3 4 5 6
P
r
e
d
i
c
t
e
d

v
a
l
u
e
s

o
f
R
e
i
n
f
o
r
c
e
m
e
n
t

(
m
m
)
Observed values of Reinforcement (mm)

Fig. 5 Scatter Diagram for Reinforcement
Model

8
18
28
38
48
58
8 18 28 38 48 58
P
r
e
d
i
c
t
e
d

v
a
l
u
e
s

o
f
D
i
l
u
t
i
o
n

(
%
)
Observed values of Dilution (%)

Fig. 7 Scatter Diagram for Dilution Model
IJAEA, Volume 1, Issue 6, pp.44-52 (2008)
Fragrance 49

14
16
18
20
22
14 16 18 20 22
P
r
e
d
i
c
t
e
d

V
a
l
u
e
s

o
f
B
e
a
d

W
i
d
t
h

(
m
m
)
Observed Values of Bead Width (mm)

Fig. 6 Scatter Diagram for Bead Width Model



4.0 RESULTS AND DISCUSSION
The mathematical model so obtained
can be used to study the direct effect of process
parameters on weld bead geometry and %
dilution are discussed below.

4.1 Effect of Process Parameters on Depth of
Penetration
Fig. 8 indicates that the depth of
penetration increases with increase in welding
current and plasma gas flow rate whereas, it
decreases with increase in welding speed and
powder feed rate.

0
1
2
3
4
5
-2 -1 0 1 2
P
e
n
e
t
r
a
t
i
o
n

(
P
)
,

m
m
Factors at coded values
I
G
H
S
F

Fig. 8 Direct Effect of Process Parameters on
Penetration

This increase in penetration is due to
increase in heat input and plasma arc force but
increase in welding speed may cause poor fusion
between the deposited metal and base metal
which results in decrease in depth of penetration.
Oscillation frequency has no significant effect on
depth of penetration.

4.2 Effect of Process Parameters on Height of
Reinforcement
From fig. 9, it is observed that an
increase in welding current, welding speed and
plasma gas flow rate results in decrease in height
of reinforcement, whereas, with an increase in
powder feed rate, the height of reinforcement
increases, which may be attributed to the fact
that increase in welding current and plasma gas
flow rate results in an increase in affected area
and equally sharp

2
3
4
5
-2 -1 0 1 2
R
e
i
n
f
o
r
c
e
m
e
n
t

(
R
)

,

m
m
Factors at coded values
I
S
F
G
H

Fig. 9 Direct Effect of Process Parameters on
Reinforcement

fall in height of reinforcement and the volume of
deposited metal per unit time increases with an
increase in powder feed rate results in increase in
height of reinforcement. The height of
reinforcement increases slightly with increase in
oscillation frequency but the effect of oscillation
frequency on reinforcement is not significant.

4.3 Effect of Process Parameters on Bead
Width
Fig. 10 shows that bead width increases
linearly when the welding current and plasma
gas flow rate increases, because with increase in
welding current and plasma gas flow rate result
in an increase in arc length and consequently
increases the bead width. The bead width
decreases as the welding speed increases. This is
due to the reason that increase in welding speed
reduces the volume of metal deposited per unit
length. If the oscillation frequency is increased,
the bead width at first increases slightly and then
sharply diminishes. The effect of powder feed
rate on bead width is not significant.
IJAEA, Volume 1, Issue 6, pp.44-52 (2008)
Fragrance
50


15
16
17
18
19
20
21
-2 -1 0 1 2
B
e
a
d

W
i
d
t
h

(
W
)
,

m
m
Factors at coded values
I
S
F
G
H

Fig. 10 Direct Effect of Process Parameters on
Bead Width

4.4 Effect of Process Parameters on
%Dilution
Fig.11 shows that dilution increases
with increase in welding current and plasma gas
flow rate and decreases with increase in welding
speed, powder feed rate and oscillation
frequency. These effects are due to the following
reasons: increase in welding current and plasma
gas flow rate results in increase in volume of
base metal melted where as, it decreases with
increase in welding speed and oscillation
frequency. If the powder feed rate is increased,
the area of reinforcement increases causing a
decline in the dilution.


10
20
30
40
50
-2 -1 0 1 2
%

D
i
l
u
t
i
o
n

(
D
)
Factors at coded values
I
S
F
G
H

Fig. 11 Direct Effect of Process Parameters on
Dilution

5. 0 CONCLUSION
The following conclusions obtained
from the above investigations are:

(i) The experiments were conducted to
develop the mathematical models using
response surface methodology to study
the direct effect of the process
parameters on % dilution and bead
geometry for stellite-6 hardfaced Gate
Valve.

(ii) The depth of penetration increases with
increase in welding current and plasma
gas flow rate and decreases with rise in
welding speed and powder feed rate.
The penetration remains constant with
increase in oscillation frequency.

(iii) The height of reinforcement decreases
with increase in welding current ,
welding speed and plasma gas flow rate
but increases with increase in powder
feed rate and no significant effect on
reinforcement with increase in
oscillation frequency.

(iv) Bead width increases with rise in
welding current and plasma gas flow
rate and decreases with rise in welding
speed. Bead width remains constant
with increase in powder feed rate. But
based on oscillation frequency, first
bead width increases upto optimum
value and further rise in oscillation
frequency decreases the bead width.

(v) Dilution increases with increase in
welding current and plasma gas flow
rate and decreases with increase in
welding speed, powder feed rate and
oscillation frequency.

REFERENCES
[1] Gregory E.N., Surfacing by Welding Alloys
Processes, Coatings and Material Selection,
Metal Construction, pp.685 -690, 1980.
[2] J .R.Davis, ASM Handbook, Vol.6, pp. 789
816, 1994.
[3] A.P.Wu, J .L.Ren, Z.S.Peng, H.Murakawa,
Y.Ueda, Numerical simulation for the residual
stresses of stellite hardfacing on carbon steel,
J ournal of Materials Processing Technology,
101, pp.70 75, 2000.
[4] P. Crook, Nonferrous Alloys and Special
Purpose Materials, Metals Handbook, ASM
International, 10
th
Edition, Vol.2, pp.446, 1993.
[5] A.K Garg, Plasma Arc Welding and
Surfacing Process, Welding Research Institute,
IJAEA, Volume 1, Issue 6, pp.44-52 (2008)
Fragrance 51

Department of Science and Technology, SERC
School on Advances in Welding Technology,
pp.101 114, Dec 10 20, 2002.
[6] K. Marimuthu, N.Murugan, Prediction and
optimization of weld bead geometry of plasma
transferred arc hardfaced valve seat rings,
Surface Engineering, Vol.19, No.2, pp.143-149,
2003.
[7] D.S.Nagesh, G.L.Datta, Prediction of weld
bead geometry and penetration in shielded metal-
arc welding using artificial neural networks,
J ournal of Materials Processing Technology,
123, pp.303-312, 2002.
[8] R.L.Deuis, J .M.Yellup, C.Subramanian,
Metal- Matrix Composite Coatings by PTA
Surfacing, Composites Science and Technology,
58 1998, pp.299-309.
[9] Thielsch H, Stainless Steel Weld Deposit
on Mild Steel and Alloy Steels, Welding
J ournal, 31, pp.37s -64s, 1952.
[10] Klueh R.L. and King J .F, Austenitic
Ferritic Weld J oint Failures, Welding J ournal,
61, pp.302s 311s, 1982.
[11] N.Murugan, R.S.Parmer, S.K.Sud. Effect of
submerged arc process variables on dilution and
bead geometry in single wire surfacing, J ournal
of Material Processing Technology, 37(1993)
767 780.
[12] N.Murugan, V.Gunaraj, Prediction and
control of weld bead geometry and shape
relationships in submerged arc welding of pipes,
J ournal of Material Processing
Technology,168(2005) 478 487.
[13] K.Manonmani, N.Murugan ,
G.Buvanasekaran, Effect of process parameters
on the bead geometry of laser beam butt welded
stainless steel sheets, International J ournal of
Manufacturing Technology,32(2007)1125
1133.
[14] N.Murugan, R.S.Parmer, Mathematical
Models for bead geometry prediction in
austenitic stainless steel surfacing by MIG
welding, International J ournal of J oining of
Materials,7, 23, pp.71-80, 1995.
[15] Ramasamy S, Gould J , Workman D,
Design of experiments study to examine the
effect of polarity on stud welding, Welding
J ournal,81, 2, pp.19s 26s, 2002.

IJAEA, Volume 1, Issue 6, pp.44-52 (2008)
Fragrance 52