Welding Process Optimization for the Customization Through
Mechanical and Metallographic Characterization: A Review with a Case
Study
L. S. Sisira K. Weerasekaralage1,*, Janith K. Wijesinghe1, S. D. Pathirana2
1
Sri Lanka Institute of Information Technology, Faculty of Engineering, New Kandy Road, Malabe Sri Lanka
2
University of Peradeniya, Peradeniya, Sri Lanka
*
Corresponding author’s email address: sisira.w@sliit.lk
Abstract
Reliability and cost-effectiveness are very important
factors in welding processes used in a wide range of
manufacturing industries. Selection of welding processes
varies widely from application to application and from
industry to industry. Generally, it is difficult to obtain
quality weldments with desired mechanical properties
economically while maintaining high reliability.
Furthermore, it is desirable to perform welding operations
that can satisfy individual applications and requirements
specifically, and produce tailor-made weldments to suit
specific requirements.
This paper presents the ability of process optimization in
customizing required quality weldments with respect to
desired mechanical properties. Gas Metal Arc Welding
(GMAW) for samples of mild steel was performed in
optimizing input weld-parameters. Welded samples,
produced with different combinations of welding
parameters, were investigated for their mechanical
properties and metallographically characterized to explain
the observed property variation. In addition to finding
optimum parameters for a quality weld, a critical welding
current (CWC) at which a brittle weldment is formed
could also be discovered during this work. It is expected
that process optimization for the customization precisely
conceivable for tailor-made applications through
modeling and simulation with software developed based
on further research to improve welding quality in the
global manufacturing industry.
Keywords: GMAW, Optimization, Welding Parameters,
Mechanical properties, Metallographic characterization
Introduction
Different welding types and processes are used in many
major segments of applications like all transportation
modes of land-ocean and air, structures of buildings,
highways and railways and machinery and appliances,
etc. Therefore, welding becomes one of the most
significant industry in the world where the continuous
developments are needed. Further, process developments
of individual welding processes within major types
(SAW, GMAW, GTAW, Laser, FSW, Submerged AW
hybrid etc.) are needed through multidisciplinary
!!"
approaches (materials, metallurgy, thermodynamics, fluid
mechanics, electronic, computer, communication etc.).
Process selection is done with respect to the concerns of
cost, labor, simplicity, efficiency, productivity and
environmental concerns in addition to the technological
factors [1].
The objective of this study is to investigate the ability of
welding process optimization that could be done in
customizing different weldments. A case study of GMAW
process optimization was attended to establish the concept
by selecting welding voltage, current and wire-feed rate
as input welding parameters. Sample weldments of
approximately similar to base metal, more toughness and
strength than the base metal, moderately tougher and for
different tensile strengths were obtained experimentally.
It was performed only for the process of GMAW and that
could be performed to other welding processes through
future research. Further, it is possible to improve
continuously with different software developed with data
acquisition systems (DAC for big data) for each process
in formulating optimized algorithms.
Welding Process Optimization
Application based optimization in customizing
Reliability, High-efficiency and cost-effectiveness
become major concerns in developing welding
technology. Table 1 summarizes a few welding
technology developments added during the last decade
and their quality assurance tests [2]. Metallic materials are
manufactured in specified lengths and cross-sections
except for special cases. It is required to obtain the
performance of a welded joint the same as the base
material or different based on the application while in use
with the particular application. Therefore, it is very
important in investigating mechanical and metallurgical
properties of welded joints for the safety, reliability, cost-
effectiveness and environmental concerns [3]. Welding
process optimization is easy with conventional materials.
But welding processes to be restudied together with the
development of new alloys and advanced materials with
different demands of applications and intended purposes
[4]. Welding machines with power sources, filler wire
Welding Process Optimization for the Customization Through Mechanical and Metallographic
Characterization: A Review with a Case Study
Table 1 Developments of welding technology and quality assurance [2]
Welding Requirements Strategy/Improvement Quality assurance/Reliability test
Application applied
Shipbuilding -Safety -Welding methods for 300 -Mechanical test
-Comply with Standards of mm thickness, double-wire -Metallographic characterization
International Maritime Organization gas metal arc welding
(IMO) (GMAW)
-High thickness Steel plates (50 mm
or more for large cargo ships)
-Corrosion resistant standard -Corrosion resistance -Corrosion test
(MSC.288(87)) by IMO welding materials and (Standard -IACS-Unified Interpretations-UI
welded joints SC258 of the International Association of
-Weld bead profile Classification Societies (IACS))
Building Safety -High Yield Strength for the -Mechanical test
Structures Seismic resistance welded joint (400 MPa or -Metallographic characterization
Towers -Weight reduction more)
-Welding positions (2G, 6G, etc.) -Welding materials
-Flux cored wires
Bridge - Safety -Corrosion resistance welded -Mechanical test
-Corrosion resistance steel bridge over joints -Metallographic characterization
the sea without bolts -Weldability with high heat
- High efficiency input
Natural Gas Tanks Safety -A new alloy with less Ni% - Mechanical test
Low-temperature Strength and high strength and welded -Metallographic characterization
Low-temperature toughness joints for the same -Crack Tip Opening Displacement (CTOD) test
Cost reduction -Improve Welding processes -Cross-weld notch wide plate test
(large-scale fracture test assuming actual welds)
Energy -Safety -High heat Input -Charpy impact test
(Offshore -High thickness Steel plates -Improved steel
Windfarms,Tidel, -Increase welding efficiency
Crude oil, etc) -Low-temperature toughness

feeders and accessories are developed with the digital
controlling and simulation techniques [5]. Mechanical
and metallographic characterization is needed to fulfill the
reliability and safety requirements of welded joints.
Transverse hill welding (THW) is the most acceptable
method for welding of castings(defective) and large thick
wall structures (hardening steels) without preheating.
N.G. Efimenko, S.N. Bartash and S.V. Artemova studied
and compared mechanical properties and structure of 25L
steel weldments without preheating, with preheating and
high-temperature tempering. It has been noted that no
significant effect on the strength and impact and ductility
properties of the HAZ for preheated and post weld heat
treated weldments compared to no preheating.
Consequently, it may be concluded that THW process
without additional technological operations is highly
promising for producing large cast components of 25L
steel [6],[7]. High strength 7075 hot-rolled aluminum
plates were subjected to friction stir process (FSP) to
improve their mechanical properties (hardening treatment
for refined grains) by Ming-Hsiang Ku, Fei-Yi Hung and
Truan-Sheng Lui. Mechanical properties of friction stir
zone were investigated for different tool rotational speeds.
The results of the tensile ductility tests indicate significant
tensile ductility loss which could be resulted in a ductile-
to-brittle transition (DBT). It was found that the ductile-
to-brittle transition (DBT) phenomenon starts at the
rotational speed of 1450 rpm and no change in average
grain size up to the rotational speed 1670 rpm and after
liquidizing temperature at 753 K. Microstructural analysis
revealed that the main reason behind the embrittlement
during tensile deformation was the interaction between
the precipitates in the friction stir induced band (FSIB)
and the micro-voids after aging with the hardening
treatment [8].
Kaiyuan Wua,b, Nian Ding, Tong Yin, Min Zeng,
Zhuoyong Liang investigated high-power double-wire
gas metal arc welding (GMAW) experiments with the
single and double pulses technology. The effects of single
and double pulses on the weld bead formation,
microstructure and mechanical properties of the weld
joints were investigated. They found that double-wire
double pulsed GMAW was more stable, producing more
perfect weld shape and higher microhardness compared to
double-wire single pulsed GMAW. Finer grain
microstructure with a higher hardness of weld pool was
obtained due to the stirring effect of alternating strong and
weak pulses on the weld pool during low-frequency pulse
cycle of the double-wire double pulsed GMAW [9]. Ajit
Hooda, Ashwani Dhingra and Satpal Sharma worked to
predict yield strength of gas metal arc welded joints of
AISI 1040 medium carbon steel. A number of 28 welding
tests were performed taking combinations of input
parameters (current, voltage, wire speed and gas flow
rate) based on low medium and high levels. They
investigated the best set of input parameters for the

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Welding Process Optimization for the Customization Through Mechanical and Metallographic
Characterization: A Review with a Case Study
maximum yield stress along the longitudinal and
transverse axis of weldments [10].
Zhongwen Wu, Chunping Huang, Fencheng Liu, Chun
Xia and Liming Ke attended to repair damaged parts of
34CrNiMo6 steel for low cost and prolong service life by
Friction Stir Processing (FSP). They used filling blocks
which are much cheaper than conventional fusion
repairing method with welding wire and powder as filling
materials. The microstructure and mechanical tests
revealed that 34CrNiMo6 steel was successfully repaired
by this method [11]. The segregation behavior, interfacial
microstructure and mechanical properties of the
dissimilar joints using two filler materials were evaluated
by Jilin Xie, Yingche Ma, Meiqiong Ou, Weiwei Xing,
Long Zhang and Kui Liu. Two dissimilar materials, a new
cast superalloy K4750 and Hastelloy X alloys were joined
by manual gas tungsten arc welding (GTAW) using two
filler materials (superalloy K4750 and Hastelloy X alloy).
The results show that both filler materials can be used to
obtain sound dissimilar joints successfully [12].
Takahiro Aito, Toshiyuki Niwa, Hiroshi Yoshida and
Naruhiko Nomura developed a software that enables us to
predict fracture of a spot-welded part in conjunction with
a general-purpose crash analysis solver. It is noted that
energy absorption in spot weldments by the crash test of
automobile bodies may not be obtained accurately due to
deformation taken place. The software named “NSafe™-
SPOT” capable of accurately predicting fracture starting
from a spot-weld has been developed. The width of the
spot weld that bears the load is considered in this software
[13].
Mahmudul H. Pavel, Nuruzzaman Rakib, Mohammad A.
Habib, Ahmed Y. Sanin, and Asif Salman attended to
determine the influence of vibration during the process of
arc welding. The vibration unit is integrated with the
workpiece of the experimental setup to measure vibration
amplitude and vibration frequency as input variables in
addition to welding speed and electrode angle. They have
found bending strength and percentage of dilution (aid of
photo and software) of the metal joint assisted with
vibration shows a better result than without vibration [14].
Optimization based on mechanical properties
Optimum welding current in TIG for Ni-base superalloy
INC738LC (precipitation strengthened alloy) which is
used in hot sections of gas turbine engines was
investigated by Saib Cherif and Boumerzoug Zakaria. The
highest ultimate tensile stress is obtained under welding
current of 40 A and it is the optimum value. It is concluded
that fracture changes from trans-granular to dimple
fracture with increasing the welding current indicates a
!!$
strong correlation of fracture mechanics to welding
current [15].
Influence of process parameters on ultimate tensile
strength (UTS) of aluminum alloy friction stir weld
(FSW) joints was investigated by Mohammad W. Dewan,
Daniel J. Huggett, T. Warren Liao, Muhammad A. Wahab
and Ayman M. Okeil. Optimized adaptive neuro-fuzzy
inference system (ANFIS) model and artificial neural
network (ANN) model were developed to predict UTS of
welded joints. Models were developed based on 73 weld
schedules with different combinations of input
petameters. Newly developed ANFIS model could be
utilized for prediction of UTS of FSW joints giving better
results than the ANN model [16].
Welded joint of two dissimilar metals using gas metal arc
welding was studied by Amit Ratan Biswas, Sadananda
Chakraborty, Partha Sarathi Ghosh and Dipankar Bose.
Yield strength, ultimate tensile strength, weld zone
hardness, weld bead thickness and reinforcement of the
welded joint of stainless steel AISI 304 and medium
carbon steel 45C8 were investigated against the input
welding variables. The experiment was designed based on
Taguchi’s method and analyzed based on ANOVA and
S/N ratio. It was found that hardness decreases, and bead
thickness increase with increasing welding current. In the
case of ultimate tensile strength and yield strength
welding current is the most significant parameter
followed by welding voltage, welding speed and gas flow
rate respectively. The approach used in the present work
may be very useful for multi-objective optimization in the
context of any machining or manufacturing process
involving not only three but also for more than three
responses. Grain structures changes of base metal, heat
affected zone and welded zone were observed and
identified more compact grains in the welded zone [17].
Imran A. Shaikh and M. Veerabhadra Rao investigated
the influence of a gas tungsten arc welding (GTAW)
process parameters like welding current, gas flow rate,
root gap and bevel angle on the distortion and tensile
strength of Aluminium alloy (AA6061). The dimension of
the workpiece is 4mm thick, 28mm in width and 150mm
in length. Filler metal ER4043 of 2.5mm in diameter, the
electrode of diameter 3mm and Argon gas used in the
process of GTAW. The experiment was carried out for
different combinations of input parameters based on the
Taguchi’s method and analyzed with ANOVA and Grey
relational approach. Optimal process parameters of
GTAW for max tensile strength and min angular
distortion were found through the analysis [18].
Weldments of AA6351 material of Gas Tungsten Arc
Welding (GTAW) with non-pulsed and pulsed current
welding at different frequencies (3Hz and 7Hz) was
Welding Process Optimization for the Customization Through Mechanical and Metallographic
Characterization: A Review with a Case Study
investigated for the mechanical properties. The tensile
strength of the joints was higher in the case of pulsed
current welding. Further studies are recommended on
different thickness of the material at different currents
comparing various properties [19].
Metallographic characterization in optimizing
Strength and toughness of materials depend on its
structure and grain size. Austenite in steel tends to grow
thermally and transform to final microstructure affecting
mechanical properties during the welding cycle.
This phenomenon of forming coarse grain austenite are
taken place most probably at the heat affected zone
adjacent to the fusion zone. Further, austenite with larger
grain size could be transformed into martensite with
continuous cooling and longer reaction time. Alloying
elements play a significant role in suppressing the
austenite grain growth. They precipitate and pin the
austenite grain boundaries before complete dissolution
causing finer grains in the microstructure. It is important
to study advanced material and the scenario of reversed
austenite behavior for the development of welding
industry [20].
High heat input welding (e.g., submerged arc welding) is
used in shipbuilding and many heavy construction sectors.
In the process, heat affected zone (HAZ) near the fusion
line is heated to 1400℃ or higher, which increases the
size of prior austenite (γ) grains in the HAZ. Hence
toughness decreases by coarsening the fracture unit. It is
reported by researchers as technique, pinning effect is
introduced to toughen HAZ by non-metallic inclusion and
intragranular transformation using oxides, like the nuclei
of ferrite transformation. The pinning effect is useful in
restraining austenite grain growth in low alloy steels to
improve the toughness of heat affected zone (HAZ). New
calculation model, consistent with the temperature
gradient of HAZ is introduced to predict austenite grain
growth behavior. Austenite grain growth simulation was
done considering the influence of grain boundary
segregation on grain boundary mobility (solute-drag
effect) considered by multi-element systems. This method
of calculation provides a better analysis of the austenite
grain growth behavior. It could be shown the possibility
of quantitatively predicting the effect of alloying elements
and welding condition [21].
Laser-MIG hybrid multi-layer welding technique
(LMHMW) has been developed in solving the problem of
large deformation, low production efficiency and the high
tendency of hot cracking in welding of thick plates.
Xiaohong Zhan, Dan Zhang, Yanhong Wei and Yuhua
Wang investigated the influence of different welding
parameters on the joint properties using optical
microscope observation, SEM, EDS and microhardness
measurement on the weldment of 19.05 mm thick plates
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of Fe36Ni Invar alloy with LMHMW process.
Experimental results illustrated that different matching of
welding parameters significantly affected the depth to
width ratio, formation of defects and HAZ width. Besides,
the weld zone consisted of two regions affected by laser
and MIG processes (center of weld seam and far away
from weld seam center) is related to different grain shape
accordingly. The peak value of microhardness appeared
at the center of weld seam since the grains in the region
affected by laser were relatively fine and the lowest
hardness value was obtained in HAZ. Further, optimized
welding parameters for LMHMW were chosen to have
quality weldment of thick Invar alloy plates [22].
Mechanical properties and microstructural
characterization were studied for circular-welded joint of
dissimilar aluminum alloys (7A05-T6 and 5A06-O) using
tungsten inert gas welding (TIG) by Wukun Wang,
Zengqiang Cao 1, Kai Liu 3, Xianglong Zhang, Kewen
Zhou and Peng Ou using scanning electron microscopy
(SEM), backscatter electron diffraction (EBSD) and
transmission electron microscopy (TEM). The tensile
strength and yield strength of the welded joints were
78.87%, 97.24% respectively compared to 5A06-O base
metal (BM). Elongation of weld reached 84.29% of 7A05-
T6 base metal. High heat input and long-term heating are
led in resulting coarse grain size in the fusion zone.
Regions with coarsened grains are identified as the
weakest area of the weld zone [23].
Van Nhat Nguyen, Quoc Manh Nguyen and Shyh-Chour
Huang investigated butt joints produced between
aluminum alloy A6061-T6 and stainless steel SUS304L
using gas tungsten arc welding (GTAW). The
macrostructure of base metals and microstructure of the
resulting specimens were analyzed by means of an optical
microscope (OM), a scanning electron microscope
(SEM), and an energy dispersive X-ray spectrometer
(EDS). The micro-hardness and tensile strength of the
welded joints were also investigated. Uniform
intermetallic layer (IMC) was found at the interface
between the stainless steel and the weld seam having a
thickness of 2 µm. It was observed that the IMC layer
consisted of different phases of Fe4Al13, Fe2Al5 and
FeAl3. Further, it was found that the Si content in the
compensating metal prevents iron diffusion into the
aluminum by hindering the development of IMC layer.
This process reduces the thickness of the IMC layer and
increases the strength of the welded joint [24].
M. Mirzaei, R. Arabi Jeshvaghani, A. Yazdipour and K.
Zangeneh-Madar studied the microstructure analysis and
mechanical properties evaluation of pulsed gas metal arc
(PGMAW) and conventional gas metal arc (GMAW)
welded joints of high strength low alloy (HSLA) steel.
Welding Process Optimization for the Customization Through Mechanical and Metallographic
Characterization: A Review with a Case Study

The microstructure of the welded joint strongly depends Case study

on the welding velocity and pulse frequency of PGMAW.
The higher amount of acicular ferrite and a small amount
of martensite present in the microstructure of weldment.
Small amounts of allotriomorphic and Widmanstätten
ferrites can be found with increased heat input. The higher
tensile strength of weld metal is due to the faster cooling
rate which leads to the formation of a higher amount of
martensite. Toughness (impact properties) of weldment
improves with the higher proportion of acicular ferrite in
deposited regions and a decrease in toughness may be due
to overall coarsen microstructure formed at a higher
transformation temperature despite a higher proportion of
acicular ferrite [25].
Gas Tungsten Arc Welding (GTAW) process was
optimized in order to obtain a weldment almost
comparable to the base metal by Young Su Park, Hyo Sik
Ham, Sang Myung Cho, and Dong Ho Bae. Among the
materials developed so far, it is known that the most
practical and applicable materials above 700℃ are Ni-
based alloys. In this study, alloy 617, which is a Ni-based
superalloy, was investigated to secure its reliability for
welding technology and technical information. The
mechanical and metallurgical properties of the base metal
and weld of Alloy 617 at high temperatures above 700℃
were examined [26].
Kamal Pal, Surjya K. Pal investigated the influence of
pulse parameters at various torch angles on tensile
properties of low carbon steel butt weld in pulsed gas
metal arc welding (P-GMAW). The peak voltage and
pulse on-time were found as the dominant parameters on
joint strength. The average joint strength was higher in
perpendicular welding and joint efficiency can be
improved significantly in both backhand and forehand
welding operations with proper selection of the pulse
parameters [27].
Experiment Procedure
The experiment was designed to do only for the GMAW
process while other welding processes could not be
attended due to non-availability resources. This will be
attended in future research. Samples of mild steel, ASME
SA216WCC (width 25 mm × thickness 5 mm) were
welded manually (Electrode Positive-EP) at 1G position
with Ø 0.8 mm diameter electrode wire using MIG
welding plant (Telwin Master MIG 270/2) with CO 2.
Chemical composition and specifications of welding
samples and filling wire are given in Table 2. The process
of manual gas metal arc welding (GMAW) was performed
with different combinations of input parameters for six set
of samples comprise of 18 workpieces for better accuracy.
The experiment was designed based on combinations of
input parameters considering welding standards, power
source specifications and deviations required for the
investigation (Table 3). Manual GMAW was performed
with specimen preparation 45⁰ V-groove joint ensuring
the ISO 9692 standard. Shielding gas flow rate and length
of the welded area were fixed throughout the process
assuming constant welding speed of manual welding.
Mechanical and Metallographic characterization
Test samples for the microstructural examination were cut
manually from the weld sections leaving sufficient time
and not to overheat the cut section minimizing effects on
the microstructure. Then test sample was mounted,
ground, polished using MP-2B grinder-polisher and
etched with the standard chemical procedure. Finally, all
the test samples were observed using an optical
microscope (Novex-OM) and saved the images of
corresponding structures without distorting the
magnification ( 500).
Table 2 Composition of base metal and feed wire

The influence of plate thickness on the microstructure and Material Base Metal Wire Electrode
mechanical properties of gas metal arc welding (GMAW)
Grade SA216 WCC ER70S-6
was investigated and compared by Lijin Huanga,
Xueming Hua, Dongsheng Wua, Zhao Jiang and Mn 0.44 1.40 - 1.85

Youxiong Ye. Grain size in welded joint increases and Si 0.18 0.80 - 1.15
strength decreases with increasing plate thickness (8 mm, Cr 0.14 -
Composition (%)

20mm and 30mm). It is due to higher peak temperatures Mo < 0.02 -

of thermal cycles. The lower strength is attributed to the V < 0.02 -
lower density of second-phase particles and more Ni 0.08 -
porosity. But the stability of the GMAW process, weld Cu 0.17 0.50
bead formation and bending test results are similar for all P 0.022 0.035
different plate thickness [28].
C 0.25 0.07 - 0.15
S 0.026 0.025

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Welding Process Optimization for the Customization Through Mechanical and Metallographic
Characterization: A Review with a Case Study
Table 3 Experiment Metrix with Results

Output Parameters for Weld Quality

Specimens Input Parameters Mechanical Testing
Visual Analysis
Hardness (HRC) ‘Avg’
Parameter set

Sample Code

Yield
Current (A)

Penetration
Voltage (V)
Wire Surface Tensile Heat Affected
Stress Toughness
Feed Quality Strength

(%)
Zone (2cm)
No.

(MPa) (J) Weld

rate (1-10) (MPa)
‘Avg’ ‘Avg’ Area
(m/min) rank ‘Avg’
Left Right

1 2(a, b, c) 40 17 3 25 2 91 17.5 29 72 75 84
2 3(a, b, c) 62 18 4 50 4 236 29 20 74 75 83
3 4(a, b, c) 76 19 6 75 6 266 33.5 63 68 68 76
4 5(a, b, c) 111 20 9 75 5 266 33 84 70 77 79
5 6(a, b, c) 143 22 13 100 9 311 39.5 84 74 73 85
6 7(a, b, c) 174 23 15 100 7 348 43.2 83 69 74 81
B Base Metal - - - - - 491 46.5 72 73

All the mechanical tests were performed at room

temperature (300K) and comply with ASTM standards.
Rockwell hardness test was performed using HR-150A
hardness tester with diamond indenter at HRC scale
(major load 150kg, minor load 10 kg and diamond 120⁰,
0.2 tip radius).
Tensile tests were carried out using a universal testing
machine (UTM 1000E) with the electro-hydraulic servo
control unit. Maximum force reading with fracture was
taken and saved for all specimens and maximum stress
was calculated. Charpy impact tests were carried out for
all welded samples using JB-300 impact testing machine
with 450 V- notch cutting machine. V-notch is machined
at the center of the weld bead and along the welding
direction. All the results are shown in Table 3.
Results and Discussion
Hardness properties and microstructure
Average Rockwell hardness values obtained under
various combinations of weld parameters are plotted in
Figure 1 using experimental results in Table 3. First and
second data sets are not considered for the analysis due to
insufficient penetration of the weld in these samples and
inconsistencies observed in the weld parameters (i.e. poor
weldments). Highest hardness is observed in the weld-
zone in all six tests. This can be ascribed to the
microstructure resulting from the higher cooling rates
experienced by the weld-zones. The maximum hardness
is achieved in both 5th and 6th set of specimens which were
welded with 143A-22V-13 m/min and 174A-23V-15
m/min, respectively. In the 5th set, the high hardness is due
to the formation of a fine-grain microstructure and in the
6th set, the formation of martensite and cementite is
responsible [17],[20],[21],[25].
Figure 1 Variations of hardness (Weld Bead and HAZ)
The metallographic phase structures of samples were
compared against those predicted by the Iron-Carbon
diagram. Phase structures obtained are shown in Table 4,
which reveal that the microstructures (Figure 3) are
almost identical. Only the weld zones of parameter set
numbers 4, 5 and 6, show a variation in phases.
The weld-area microstructure is dependent on the heat
input and cooling rate, and contain a combination of grain
boundary ferrite, side-plate ferrite, acicular ferrite, bainite
and martensite.
These features are fairly consistent with the
microstructures obtained with continuous cooling of low
carbon steel. At the start of cooling of the weld, grain
boundary ferrite formation is initiated and subsequently,
diffusion rates decrease with further cooling to low
temperatures. Acicular ferrite nucleates and grows with
intragranular inclusions [25], [20]. On the other hand,
higher heat input enhances diffusion and promotes grain
boundary ferrite. However, under higher cooling rates, the
nucleation rate is faster and, hence, transformations begin
earlier. Therefore, comparatively, the samples which have
experienced a low-temperature regime show a mixed
microstructure comprising acicular ferrite and lath-
martensite [20],[21],[25].

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Welding Process Optimization for the Customization Through Mechanical and Metallographic
Characterization: A Review with a Case Study

Toughness properties This can be due to faster cooling resulting from the quick
manual welding procedure which tends to produce more
Toughness results are shown in Table 3. Highest impact
martensite and less ferrite [20],[21],[25] and refer Figure
strength is observed with the 6th set of specimens which
3. A similar observation can be made with the 5th
could be due to the formation of martensite and cementite,
specimen-sets too, which have received comparatively
or acicular ferrite in those samples.
little lower heat input.
However, impact toughness is decreased slightly in the 6th
set of specimens and this can be due to the presence of
grain boundary ferrite and ferrite side plates which
provide crack propagation paths [20],[25]. Determination
of the fracture mechanisms responsible for impact failure,
however, is beyond the scope of this work.
Table 4 Metallurgical analysis of specimens
Parameter
Set No.

HAZ 1cm Weld Area HAZ 1cm Base Metal

Left Right

Ferrite + Ferrite + Ferrite +

Coarse Figure 2 Behavior of UTS and Yield Strength
1 Pearlite Pearlite Pearlite
Pearlite
(0.5%) (0.1%) (0.2%)
Set 4 Set 5
Pearlite + Pearlite + Ferrite +
Coarse
2 Cementite Cementite Pearlite
Pearlite
(5%) (5%) (0.2%)
Ferrite + Ferrite + Ferrite +
3 Pearlite Fine Pearlite Pearlite Pearlite
(0.5%) (0.5%) (0.2%)
Set 6 Base Metal
Ferrite + Ferrite +
Ferrite + Coarse
4 Pearlite Pearlite
Pearlite (5%) Pearlite
(5%) (0.2%)
Ferrite + Ferrite +
Ferrite + Very Fine
5 Pearlite Pearlite
Pearlite (5%) Pearlite Figure 3 Microstructures of samples ( )
(5%) (0.2%)

Pearlite +
Martensite +
Pearlite + Ferrite + Conclusions
6 Cementite Cementite Pearlite
(5%)
Cementite
(5%) (0.2%)
Best quality of weld with high tensile stress and ductile is
obtained when the current, voltage and wire federate are
143A, 22V, and 13 m/min respectively and this result is
verified by metallographically (Table 3, Table 4, Table 5
Tensile properties
Figure 1, Figure 2 and Figure 3).
Tensile properties of welded samples are plotted in Figure
Required mechanical properties of a welded joint can be
2 which are based on the experimental results shown in
obtained by varying input parameters (Table 5 with
Table 3. The best ultimate tensile stress and yield stress
respect to the samples 3,4,5 and 6). But further research is
properties in the weld zone are obtained in the 6th set of
needed with a higher number of input variables and
specimens according to Table 3.
samples in generalizing.
Table 5 Mechanical Properties of weldment
Yield stress, Ultimate tensile stress, toughness and
Sample Input Properties of Weld pool
Set Combination
hardness are increased by increasing welding current
UTS Toughness Hardness
No. Current/ Rank Strength Rank (Figure 2 and Table 5).
Voltage Rank
Wire feed rate % % % Brittle joints are formed with a particular welding current
Base Metal 100 100 100 that could be considered as “critical welding current”
3 76-19-6 54 91 103 (CWC) for brittle weld formation with higher toughness
4 11-20-9 54 112 106
5 143-22-13 63 112 112 strength (Table3, Table4, Table5 and Figure 1). Further
6 174-22-15 71 111 111 research is needed in generalizing [8].

!!(
Welding Process Optimization for the Customization Through Mechanical and Metallographic
Characterization: A Review with a Case Study
It could be stated that welding process optimization for
the customization (for tailor-made applications) is
precisely conceivable through modeling and simulation
software. Further, data acquisition systems (DAC for big
data) could be installed for each welding processes in
formulating algorithms through further research.
Acknowledgment
The authors gratefully acknowledge the faculty of
engineering and graduate studies & research of Sri Lanka
Institute of Information Technology (SLIIT), all the
advisors and supporting staff for the assistance provided.
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