Ijmet 07 05 018

International Journal of Mechanical Engineering and Technology (IJMET)
Volume 7, Issue 5, SeptemberOctober 2016, pp.156176, Article ID: IJMET_07_05_018

Available online at
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ISSN Print: 0976-6340 and ISSN Online: 0976-6359
IAEME Publication
EFFECT OF WELDING CURRENT ON WELDING

SPEED AND ULTIMATE TENSILE STRENGTH (UTS)
OF MILD STEEL
Syambabu Nutalapati
Research Scholar, M.E (Machine Design), (Ph.D), JNTUK, India.
Dr. D. Azad
Professor, Aitam Tekali, Srikakulam District, India.
Dr. G. Swami Naidu
Professor and Vice-Principal (Administration), Department of Metallurgical Engineering,
JNTUK-UCEV, India.
ABSTRACT
Welding is a fabrication or sculptural process that joins materials, usually metals or
thermoplastics, by causing fusion, which is distinct from lower temperature metal-joining techniques
such as brazing and soldering, which do not melt the base metal. In the heavy as well as small
industries, welding is widely used by metal workers in the fabrication, maintenance and repair of
parts and structures. Welding current is the most influencing parameter in welding process which
controls the depth of fusion; the electrode feed rate and depth of penetration. The amount of heat
developed during welding depends upon the current used for a given size of electrode and filler wires.
It is therefore essential that a correct current is used to produce good quality of weld and reduce the
distortion problems on the job.
The effect of welding current on welding speed and ultimate tensile strength of mild steel material
is investigated in this paper. Mild steel weldment was welded under varying welding current i.e. 90,
95 & 100 ampere by using MMAW process in 1G position. The edge preparation, electrode diameter
and electrode type, CCV, welding technique, polarity and welder remained constant during the test.
It was observed that with increase in welding current melting rate of electrode was increased hence
welding time was reduced.
Key words: MMAW, welding current, welding speed, ultimate tensile strength (UTS).
Cite this Article: Syambabu Nutalapati, Dr. D. Azad and Dr. G. Swami Naidu, Effect of Welding
Current on Welding Speed and Ultimate Tensile Strength (UTS) of Mild Steel. International Journal
of Mechanical Engineering and Technology, 7(5), 2016, pp. 156176.
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Effect of Welding Current on Welding Speed and Ultimate Tensile Strength (UTS) of Mild Steel
1. INTRODUCTION
1.1. Mild Steel
Steel is any alloy of iron, consisting of 0.2% to 2.1% of carbon, as a hardening agent. Besides carbon, many
other metals are a part of it. They include chromium, manganese, tungsten and vanadium. Other than a
maximum limit of 2% carbon in the manufacture of carbon steel, the proportions of manganese (1.65%),
copper (0.6%) and silicon (0.6%) are fixed, while the proportions of cobalt, chromium, niobium,
molybdenum, titanium, nickel, tungsten, vanadium and zirconium are not. What is known as mildest grade
of carbon steel or mild steel is typically the variety which has a comparatively low amount of carbon (0.05%
- 0.26%). Mild steel is a very popular metal and one of the cheapest types of steel available. Its found in
almost every metal product. This type of steel contains less than 2 percent carbon, which makes it magnetize
well. Since its relatively inexpensive
Properties of metals can be classified mainly into:
Chemical properties
Physical properties
1.1.1. Chemical Properties

Corrosion will spoil the metal surface due to the effect of various elements in the atmosphere and water.
Oxidation is the formation of metal oxides which occur when oxygen combines with metals.
Reduction refers to the removal of oxygen from the surrounding molten puddle to reduce the effect of
atmospheric contamination.
1.1.2. Physical Properties

Physical properties are those, which affect metals when they are subjected to heat generated by welding such
as:
Melting point
Thermal expansion
Thermal conductivity
Grain growth
Melting point is the degree of temperature, when a solid metal changes into liquid. Melting points of
some metals are given below:
Mild steel 1500 to 1530C

Cast iron 1150C
Material
Mild steel
0.14
Mn
0.76
si
0.28
0.013
0.010
Table 1.1 composition of mild steel
1.2. Joint Types

The American Welding Society defines a joint as the manner in which materials fit together. There are five
basic types of weld joints but butt welding is used in this operation
1.2.1. Butt Joint (Single V)
Butt joints are used where high strength is required. They are reliable and can withstand stress better than
any other type of weld joint. To achieve full stress value, the weld must have 100 percent penetration through
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Syambabu Nutalapati, Dr. D. Azad and Dr. G. Swami Naidu
the joint. This can be done by welding completely through from one side. The alternative is working from
both sides, with the welds joining in the centre.
Figure 1.1 single V butt joint
2. EXPERIMENTAL PROCEDURE
MMA/TIG Welding Machine with a 400A capacity. In this investigation Mild steel alloy plate of dimension
90mm 25mm 6mm (figure 1) were taken for SMAW welding technique. These plates are cleaned of dirt,
grease and other foreign materials and were cut into the required dimensions by power hacksaw. Edge
preparation is carried out where single V edge is prepared for a bevel angle of 30, 45, 60 and square butt
joint plates were prepared by smoothing their faces. In all the cases the root gap of 1 mm and root of 1mm
was maintained. The mild steel plates are placed on welding table and in order avoid the undesired distortion
to the minimal the right size of stiffeners was provided at critical locations where the welding process is
carried out.
There are 6 numbers of specimens were prepared from SMAW process viz., single V butt joint. The 6
specimens of single V joint design at six different values of welding current (specimen code 1V at 90 amps
and with angle 30, 2V at 100 amps with angle 45, 3V at 110 amps with angle 60,)
In this process all the various welding parameters such as the arc voltage, number of passes, welding speed, wire
feed rate, arc time and welding current were recorded during the welding of each specimen only welding current was
varied during the welding of specimens, to study the effect of welding current on the tensile strength, yield strength
and elongation of the weldment. Having finished the welding of the joints in order to measure the tensile strength,
welded plates were cut using hacksaw and then machined to the required dimensions to make the tensile test pieces
with the help of the workshop technology. The dimensions of a tensile test specimen shown
At the same time the different angles of specimens are tested by universal testing machine for finding
the strength and also the ansys tutorial and CATIA V5 software are used in this operation with applying of
different load. At last getting the result which is the best strength or capability comparing to other specimen
and the specimens are 30 single V butt joint specimens, 45 single V butt joint specimen, 60 single V butt
joint specimen
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2.1. Geometrical Properties
Figure 2.1 Sketched diagram of 300 V-grooved specimen
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In this investigation Mild steel plate of dimension 90mm 25mm 6mm
SMAW
Mild steel electrode
Single v groove butt joint
Inclination angle 60
Curve of 12mm radius
These plates are cleaned of dirt, grease and other foreign materials and were cut into the required
dimensions by manual hacksaw blade. Edge preparation is carried out where single V edge is prepared for a
bevel angle of 60 and square butt joint plates were prepared by smoothing their faces.
2.2. Tensile Test on a Metal

2.2.1. Required Apparatus
Universal Testing Machine (UTM)

Mild steel specimens
Graph paper
Scale
Vernier Caliper
2.2.2. After Testing
Limit of proportionality
Elastic limit
Yield strength
Ultimate strength
Youngs modulus of elasticity
Percentage elongation
Percentage reduction in area.
2.2.3. Procedure
Measure the original length and diameter of the specimen. The length may either be length of gauge section
which is marked on the specimen with a pre-set punch or the total length of the specimen.
Insert the specimen into grips of the test machine and attach strain-measuring device to it.
Begin the load application and record load versus elongation data.
Take readings more frequently as yield point is approached.
Measure elongation values with the help of dividers and a ruler.
Continue the test till Fracture occurs.
By joining the two broken halves of the specimen together, measure the final length and diameter of specimen.
2.2.4. Observation
After testing the dimensions of the specimen are
A) Original dimensions: Mild steel plate of dimension 90mm 25mm 5.5mm
Length = 90
Thickness = 5.5
Area: 9025=2250mm2
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B) Final Dimensions: 92mm 25mm 6mm

Length = 92
Thickness =6
Area: 9225 = 2300
2.3. Observation Table

Specimen
Angle
Load(N)
Original
Extension
Peak load
Strain
A1
30
313
38
39
1.15
1.02
B1
30
475.7
39
40
1.68
1.02
A2
60
487
38
39
1.72
1.02
A3
45
453
38
40
1.72
1.05
B3
45
300
38
39
1.60
1.02
Table 2.1 observation table
2.4. Specimen Code A1
Percentage reduction in area= Original area-area at fracture / Original area
(1712-1698)/1706= 15.97%
Percentage elongation= (Final length (at fracture) original length) / Original length
(92-90) / 90 = 2.63%
Cross head travel at break: 7.10 mm
Tensile strength: 31.94 N/mm2

2.4.1. Graph between Stress Strain Curve
Figure2.4 graph between stress vs strain curve-A1
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2.4.2. Graph between Load and Cross Head Travel Curve
Figure 2.5 Graph between load and cross head travel curve-A1
2.4.3. Graph between Stress and Cross Head Travel Curve (Elongation)
Figure 2.6 Graph between stress and cross head travel curve (elongation) -A1
2.5. Specimen Code B1
(1706-1698)/1706= 19%
(92-90) / 90 =2.56%
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Figure 2.7 Graph between stress strain curves-B1
Figure 2.8 Graph between load and cross head travel curve-B1
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Figure 2.9 Graph between stress and cross head travel curve (elongation) -B1
15.97%
2.63%

Tensile strength: 47.78 N/mm
Figure 2.10 Graph between stress strain curves-A2
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8.33%
(92-90) / 90 = 5.26%

Figure 2.13 Graph between stress strain curves-A3
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2.8. Specimen Code B3
15.97%
(92-90) / 90 = 2.63%

Figure 2.15 Graph between stress strain curves-B3
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Figure 2.16 Graph between load and cross head travel curve-B3
Figure 2.17 Graph between stress and cross head travel curve (elongation) -B3
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2.9. Testing Specimen
Figure 2.18 Testing specimen
2.10. Precaution
If the strain measuring device is an extensometer it should be removed before necking begins.
Measure deflection on scale accurately & carefully
3. RESULT
Single V joint design of butt joint at 30 inclination angle have depict high
Maximum tensile strength value
Cross head travel at break = 6.40mm

Ultimate tensile strength = 47.78 N/mm2
Percentage of elongation = 2.63
Percentage reduction in area = 15.97
Peak load = 1.72KN
4. DESIGN AND ANALYSIS

4.1. CATIA Model
Figure 3.1 3d model of 300 V-grooved specimen.
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Figure 3.2 3d model of 450 V-grooved specimen
Figure 3.3 Sketched diagram of 600 V-grooved specimen.
4.2. Introduction to FEA

Structural analysis consists of linear and non-linear models. Linear models use simple parameters and
assume that the material is not plastically deformed. Non-linear models consist of stressing the material past
its elastic capabilities. The stresses in the material then vary with the amount of deformation as in.
Vibrational analysis is used to test a material against random vibrations, shock, and impact. Each of
these incidences may act on the natural vibrational frequency of the material which, in turn, may cause
resonance and subsequent failure.
Fatigue analysis helps designers to predict the life of a material or structure by showing the effects of
cyclic loading on the specimen. Such analysis can show the areas where crack propagation is most likely to
occur. Failure due to fatigue may also show the damage tolerance of the material.
Heat Transfer analysis models the conductivity or thermal fluid dynamics of the material or structure.
This may consist of a steady-state or transient transfer. Steady-state transfer refers to constant thermo
properties in the material that yield linear heat diffusion.
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Material Properties
A parts response is determined by the material properties assigned to the part.
Depending on the application, material properties can be linear or nonlinear, as well as temperature-dependent.
Linear material properties can be constant or temperature-dependent, and isotropic or orthotropic.
Nonlinear material properties are usually tabular data, such as plasticity data (stress-strain curves for different
hardening laws), hyper elastic material data.
To define temperature-dependent material properties, you must input data to define a property-versustemperature graph.
Although you can define material properties separately for each analysis, you have the option of adding your
materials to a material library by using the Engineering Data application. This allows quick access to and reuse of material data in multiple analyses.
In the present work, a typical Finite Element (FE) model of a wind turbine blade was developed and
modal were carried out using ANSYS. To simulate the behavior of the blade of FE model summary is given
below.
Number of elements
= 34999
Number of nodes
= 37522
ELEMENT TYPE
=MESH 200
Figure 3.4 Geometry model imported into ansys 16.0 and after meshing
Figure 3.5 Total deformation of 30 0 grooved specimen with welding
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Figure 3.6 Stresses of 30 0 grooved specimen with welding
Figure 3.7 Strain of 30 0 grooved specimen with welding
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5. RESULTS AND DISCUSSION

The tensile strength of the joints was evaluated. The specimens were tested and the
Results were presented below
5.1. Tensile Strength of the Joint at Welding Time

Specimen
code
Inclination
Angle
Joint design
Current
(amps)
Arc
Time(sec)
Welding speed
(mm/min)
A1
30
Single v
90
45
142.66
B1
30
Single v
110
40
152.26
A2
60
Single v
90
36
179.35
A3
45
Single v
90
30
193.56
B3
45
Single v
110
28
199.76
Table 4.1 Tensile strength of the joint at welding time
5.2. Effect of Welding Current on Ultimate Tensile Strength

Specimen
code
Inclination
Angle
Cross head
travel brake
(m)
Ultimate Tensile
Strength(N/mm2)
Percentage
Elongation
Percentage
reduction in
area
A1
30
7.10
31.94
2.63
15.97
B1
30
8.40
34.72
2.56
19.00
A2
60
6.40
47.78
2.63
15.97
A3
45
10.90
44.44
5.26
8.33
B3
45
7.40
29.44
2.63
15.97
Table 4.2 Effect of welding current on tensile strength
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5.3. Effect of Welding Current and Joint Design on Ultimate Tensile Strength
From the values of UTS (ultimate tensile strength) obtained for joint design single V at 90amp, 100amp,
110amp etc. it is observed that 110amp weldment depicted maximum ultimate tensile strength when compare
to weldment of 90amp, 100amp and 120amp.Compartively the single V joint design depict maximum value
of ultimate tensile strength 47.78N/mm2.at 90 amp with 60 angle than. From the above analysis it was
observed that the single V joint has maximum tensile strength in comparison to other joint design of angles.
It was also observed that the tensile strength increases with increase in current up to 110 amp which was
optimum value to obtain maximum ultimate tensile strength in case of single V joint, it means that the rate
at which the welding electrode is melted, the amount of base metal melted, dilution, depth of fusion, the
deposition rates, the depth of penetration was good at this value and optimum weldability can be achieved
at joint design of single V current 110 amp, arc time 36sec, welding speed 149.35 mm/min.
5.4. Effect of Welding Current on Arc Time

It can be clearly seen from the table that the arc time is maximum in case of other angle V joint in comparison
to single V at 60. In single V joint most of the welding was done on one side of the weldment, only back
gouging is done after grinding at the back of the joint to completely fuse the edges.
5.6. Effect of Welding Current on Welding Speed

The welding speed is maximum in case of double V joint because welding speed depends upon the current
and the thickness of the material. From the above graph it can be observed that there is an increase in welding
speed with an increase in welding:
250
200
150
Inclination
current
100
weld speed
50
0
A1
B1
A2
A3
B3
Graph 4.1 Current vs. weld speed
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70
60
50
40
inclination
% of area reduction
30
ultimate tensile strength
20
10
0
A1
B1
A2
A3
B3
Graph 4.2 Inclination vs. UTS
120
100
80
current
60
% of area reduction
ultimate tensile strength
40
20
0
A1
B1
A2
A3
B3
Graph 4.3 Current vs. UTS
6. CONCLUSION
At the welding current of 90amp the tensile strength was maximum for single V joint design in comparison
with weld carried out of 100amp and 110amp. And also in comparison to other types of joint design, i.e.
double V and square butt joint, the ultimate tensile strength of single V joint design was maximum.
With the increase in welding current which was taken as a variable parameter the ultimate tensile strength
47.78N/mm2, yield strength 340.23MPa and percentage elongation of 2.63 was recorded. Maximum/optimum
value of tensile strength of single V joint design was obtained when welding speed was 179.35mm/min.
Hence it can be concluded that the ultimate tensile strength in case of the single V joint was maximum as a
result of correct fusion between weld metal and base metal, right joint design and edge preparation for this
type of material thickness.
Also, it may be concluded that with the increase in welding current the UTS will increase until an optimum
value. The ansys value and experimental values are approximately same i.e. the single V joint design at 30
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with 90 amp current, the max tensile strength is 47.78N/mm2 comparing to other angles and the code of
specimen is A2
REFERENCE
[1]
Prof. S R Satish Kumar and Prof. A R Santha Kumar IIT Madras, Design of steel structures.
[2]
Svensson L. E. Exploiting advances in arc weld technology by weld institute, Wood head Publishing
Limited, 1999.
[3]
Sampath K.; Constraints-Based Modelling Enables Successful Development of a Welding Electrode

Specification for Critical Navy Applications; August 2005; Welding Journal; Pg 131- 138.
[4]
Vincent Van Der Mee, Fred Neessen, Development of High Strength Steel Consumables from Project to
Product, Lincoln Smitweld bv, The Netherlands, 2007.58
[5]
Arrellb D., Heobel M., Larssonb R., Marchantc G. and Henderson M.B.; Nickel-Based
[6]
Super alloy Welding Practices for Industrial Gas Turbine Applications, Science and technology of
welding and joining, 2001.
[7]
Baun E., Chovet C., Leduey B. and Bonnet C.; Consumables for welding of (very) high strength steels
mechanical properties of weldments in as-welded and stress relieved applications.
[8]
Kapoor Ashish and Ogborn Jonathan; Development of high strength SMAW consumables for SBD
applications; Proceedings of the 18th International Offshore and Polar Engineering Conference, Canada;
July 6-11 2008.
[9]
P. Govindarao, Dr. P. Srinivasarao, Dr. A. Gopalakrishna and C V Sriram, Improvement of Tensile

Strength of Butt Welded Joints Prepared by Vibratory Welding Process. International Journal of
Mechanical Engineering and Technology (IJMET), 4(4), 2013, pp.5361.
[10]
Babu S. S. and Vitek J. M.; A Novel Methodology for Welding Consumable Design and Optimization;
1999; Technology Research Program, Energy Research Laboratory.
[11]
Gandy David W., Findlan Shane J. and Viswanathan R.; Weld Repair of Steam Turbine Casings and
PipingAn Industry Survey; May 2001; Vol. 123; Journal of Pressure Vessel Technology; Pg 157-160.
[12]
Kane S. F., Farland A. L., Siewert T. A. and McCowan C. N.; Welding Consumable Development for a
Cryogenic (4 K) Application; August 1999; Welding Journal; Pg 292-300.
[13]
Inoue Hiroshige, Matsuhashi Ryo, Tadokoro Yutaka, Fukumoto Shigeo, Hashimoto Takeshi, Mizumoto
Manabu and Nagasaki Hajime; Development of Welding Consumables for High-Corrosion Resistant
Stainless Steel NSSC260A for Chemical Cargo Tankers; January 2007; No.95; Nippon Steel Technical
Report.
[14]
Zacharia T., Vitek J. M., Goldakf J. A., DebRoy T. Rappazll A., M. and Bhadeshia H. K. D. H.; Modeling
of fundamental phenomena in welds; 1995;Modelling Simulation
[15]
Dalip Kumar, Antariksha Verma, Sankalp Kulshrestha and Prithvi Singh, Microstructure and Mechanical
Properties of Mild Steel-Copper Joined by Friction Welding. International Journal of Mechanical
Engineering and Technology (IJMET), 4(5), 2013, pp.295300.
[16]
Investigation of Welding Parameters On Mechanical Properties of Different Welding Joints of Mild

Steel1Bhaskar Vishwakarma, 2Manish Verma & 3Tribhuwan Kishor Mishra 1&2CEC, BILASPUR,
3GGITS JABALPUR
[17]
Gandy David, Smith Richard and Lau Ming; SMAW Temper bead Weld Repair Without Grinding; August
2001; Paper 2052; Transactions SMiRT 16, Washington DC.
[18]
Sopousek Jiri, Foret Rudolf and Jan Vit; Simulation of Dissimilar Weld Joints of Steel
[19]
Mitra U., Chai C. S. and Eagar T. W.; Slag Metal Reactions during Submerged Arc
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International Journal of Mechanical Engineering and Technology (IJMET)

Volume 7, Issue 5, SeptemberOctober 2016, pp.156176, Article ID: IJMET_07_05_018

EFFECT OF WELDING CURRENT ON WELDING

1.1.1. Chemical Properties

1.1.2. Physical Properties

Mild steel 1500 to 1530C

Table 1.1 composition of mild steel

1.2. Joint Types

Syambabu Nutalapati, Dr. D. Azad and Dr. G. Swami Naidu

Figure 1.1 single V butt joint

2.1. Geometrical Properties

Figure 2.1 Sketched diagram of 300 V-grooved specimen

Figure 2.2 Sketched diagram of 450 V-grooved specimen

Figure 2.3 Sketched diagram of 600 V-grooved specimen

Syambabu Nutalapati, Dr. D. Azad and Dr. G. Swami Naidu

In this investigation Mild steel plate of dimension 90mm 25mm 6mm

2.2. Tensile Test on a Metal

Universal Testing Machine (UTM)

2.2.2. After Testing

B) Final Dimensions: 92mm 25mm 6mm

2.3. Observation Table

Table 2.1 observation table

2.4. Specimen Code A1

Percentage reduction in area= Original area-area at fracture / Original area

Cross head travel at break: 7.10 mm

Tensile strength: 31.94 N/mm2

Figure2.4 graph between stress vs strain curve-A1

Syambabu Nutalapati, Dr. D. Azad and Dr. G. Swami Naidu

2.4.2. Graph between Load and Cross Head Travel Curve

2.5. Specimen Code B1

Percentage reduction in area= Original area-area at fracture / Original area

Cross head travel at break: 5.2 mm

Tensile strength: 46.67 N/mm2

2.5.1. Graph between Stress Strain Curve

Figure 2.7 Graph between stress strain curves-B1

2.5.2. Graph between Load and Cross Head Travel Curve

Syambabu Nutalapati, Dr. D. Azad and Dr. G. Swami Naidu

2.6. Specimen Code A2

Percentage reduction in area= Original area-area at fracture / Original area

Cross head travel at break: 4.9 mm

2.6.1. Graph between Stress Strain Curve

Figure 2.10 Graph between stress strain curves-A2

2.6.2. Graph between Load and Cross Head Travel Curve

Syambabu Nutalapati, Dr. D. Azad and Dr. G. Swami Naidu

2.7. Specimen Code A3

Percentage reduction in area= Original area-area at fracture / Original area

Cross head travel at break: 10.90 mm

2.7.1. Graph between Stress Strain Curve

Figure 2.13 Graph between stress strain curves-A3

2.7.2. Graph between Load and Cross Head Travel Curve

2.8. Specimen Code B3

Percentage reduction in area= Original area-area at fracture / Original area

Cross head travel at break: 7.40 mm

2.8.1. Graph between Stress Strain Curve

Figure 2.15 Graph between stress strain curves-B3

Syambabu Nutalapati, Dr. D. Azad and Dr. G. Swami Naidu

2.8.2. Graph between Load and Cross Head Travel Curve

2.9. Testing Specimen

Figure 2.18 Testing specimen

Cross head travel at break = 6.40mm

4. DESIGN AND ANALYSIS

Figure 3.1 3d model of 300 V-grooved specimen.

Syambabu Nutalapati, Dr. D. Azad and Dr. G. Swami Naidu