Paper ID: 1524

Optimization of Robotic GMAW Parameters for Enhanced Quality of 3G Mild Steel Welds

 

Muhammad Ilham Sukor1, Hafiz Ghazali1*, Muhammad Mohamed Salleh1, Mohd Shukri Mokhtar1, Abdul Hamid1, Agung Setyo Darmawan2

1Faculty of Technical and Vocational Education, Universiti Tun Hussein Onn Malaysia, Batu Pahat, 86400, MALAYSIA

2Department of Mechanical Engineering, Faculty of Engineering, Universitas Muhammadiyah Surakarta, Jl. Ahmad Yani, Tromol Pos 1

  Pabelan, Surakarta 57162, Indonesia

 

*Corresponding author: hafizg@uthm.edu.my

 

Abstract

With the increasing adoption of robotic welding systems in industrial manufacturing, understanding the precise control of welding parameters in this difficult position has become essential to ensuring consistent welding quality. This study focuses on evaluating the effects of key Robotic Gas Metal Arc Welding (GMAW) parameters namely current, voltage, and wire feed rate on weld bead appearance, root penetration, and tensile strength when applied to mild steel plates. The research aims to identify the optimal parameter combination capable of maximizing weld quality while minimizing defects, enabling more reliable robotic welding performance in the 3G position. To achieve this, the Taguchi Method was employed to design a robust and systematic experimental framework, allowing efficient parameter variation and analysis. An ABB IRB 1520ID robotic arm integrated with a Fronius TPS 320i robotic GMAW machine was used to ensure repeatability and control throughout the welding trials. A total of nine experimental specimens were produced based on an L9 orthogonal array, with each specimen subjected to visual non-destructive testing (NDT) to assess surface discontinuities and destructive testing (DT) to determine mechanical integrity. Analysis of the experimental data revealed that welding current, voltage, and wire feed rate significantly influence weld penetration and strength in the 3G position. The study identified 110 A of current, 17.9 V of voltage, and a wire feed rate of 2.7 m/min as the optimum parameter settings, achieving a superior tensile strength of 403 N/mm² and eliminating root penetration defects. Furthermore, optimal visual quality was quantified at 80 A, which yielded a 100% defect-free weld bead and root pass. Overall, the findings demonstrate that by establishing an optimized parameter window, this research contributes to improved process reliability, enhanced weld quality, and greater industrial applicability.

Keywords: robotics welding, gas metal arc welding, welding parameters, non-destructive testing, root penetration.

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