Establishing empirical relationships and process parameter optimization of tungsten inert gas welded butt joints of nickel-based alloy using statistical approach of regression analysis and response surface methodology

ABSTRACT

This investigation presents the process parameter optimisation of high-frequency concentrated arc TIG (HFCA-TIG) welded butt joints of nickel-based alloy 718 using response surface methodology to enhance the performance characteristics of joints. The polynomial regression equations of second order were formulated for predicting the performance characteristics of alloy 718 butt joints from the process parameters. Analysis of variance (ANOVA) was performed to determine the significant process parameters and to estimate the proficiency of empirical relationships. The experimental and predicted results were compared for validation of empirical relationships. It disclosed less than 4% error at 95% confidence level. The numerical and graphical optimisation complying the optimisation criteria was executed to find the optimum conditions of process parameters depending on the desirability function. The interaction effect of process parameters on performance characteristics of joints was analysed from three-dimensional response surface plots.

KEYWORDS:

• HFCA-tig welding
• alloy 718
• optimisation
• response surface methodology (rsm)
• tensile properties

Acknowledgments

This research work is funded by the Indian Space Research Organisation (ISRO), Department of Space, India through ISRO RESPOND scheme (Project No.ISRO/RES/3/728/16-17).

Date Availability Statement

The data that support the findings of this study are openly available in Mendeley Data at http://doi.org/0.17632/z2n73gkxgm.1 (Sonar 2020f).

Disclosure statement

No potential conflict of interest was reported by the author(s).

Additional information

Funding

This work was supported by the Indian Space Research Organisation [ISRO/RES/3/728/16-17].

Notes on contributors

Tushar Sonar

Dr. Tushar Sonar is working as a Technical Manager in GEE Limited Kalyan, Maharashtra State, India. He completed his Ph.D. Manufacturing Engineering (Welding) from Annamalai University, Annamalai Nagar, Tamil Nadu State, India in 2021. He is also a Board Member of Studies for Mechanical Engineering in autonomous Maharashtra Institute of Technology, Aurangabad. He is a recipient of the ISRO RESPOND Research Fellowship from the Indian Space Research Organization (ISRO), Department of Space, Government of India. His research interests include Welding and Joining, Additive Manufacturing and Heat Treatment of Metals.

Visvalingam Balasubramanian

Dr. Visvalingam Balasubramanian is working as a Professor & Head in the Centre for Materials Joining & Research (CEMAJOR) Department of Manufacturing Engineering, Annamalai University, Annamalai Nagar, Tamil Nadu State, India. He completed his Ph.D. from the Indian Institute of Technology Madras (IITM), Chennai in 2000. He has 28 years of teaching experience and 25 years of research experience. He has supervised 26 Ph.D. scholars. His areas of interest are Materials Joining, Surface Engineering and Nanomaterials.

Sudersanan Malarvizhi

Dr. S. Malarvizhi is working as a Professor in the Centre for Materials Joining & Research (CEMAJOR), Department of Manufacturing Engineering, Annamalai University, Annamalai Nagar, Tamil Nadu State, India. She obtained her PhD from Annamalai University, Chidambaram 2008. She has 24 years of teaching experience and 20 years of research experience. Her areas of interest are welding metallurgy and materials science. She is a recipient of Tamil Nadu Young Women Scientist Award in 2012.

Thiruvenkatam Venkateswaran

Dr. Thiruvenkatam Venkateswaran is a scientist at Materials and Metallurgy Group (MMG) of Vikram Sarabhai Space Centre (VSSC), Thiruvananthapuram, India. He obtained his Ph.D. from Indian Institute of Technology Madras, India in 2018. He served as visiting research scholar at Seoul National University (SNU), South Korea before joining VSSC. At present, he is actively engaged in various developmental activities connected to the upcoming launch vehicles of Indian Space Research Organization (ISRO). His research interest includes brazing of metallic and ceramic materials, welding of aerospace materials, high temperature materials, and ultra-high temperature ceramics.

Dhenuvakonda Sivakumar

Dr. Dhenuvakonda Sivakumar is a Scientist at Materials and Metallurgy Group (MMG) of Vikram Sarabhai Space Centre (VSSC), ISRO, Thiruvananthapuram, Kerala State, India. He obtained his Ph.D. from IIT Mumbai in the area of welding. He is currently heading the Heat Treatment and Welding Metallurgy division in VSSC. He has more than 25 years of research and industrial experience in welding and brazing of stainless steels and superalloys. His research interests include development of high strength steels, maraging steels, welding of steels, superalloys and aluminium alloys and vacuum brazing.