Parametric modeling of metal inert gas (MIG) welding process using second-order regression model analysis

Welding parameters play an important role in determining the quality of a weld joint. In this present study, an attempt was made to determine the correlation of the welding parameters and weld quality of MIG welding process using regression analysis of a full factorial design experiment. Welding speed and arc voltage were varied during the fabrication of T-joint AA 6082-T6 aluminium alloys. Weld quality was analyzed in terms of tensile strength and penetration depth. Considering all terms, a linear regression analysis was employed to develop input-output correlation. From the analysis of ANOVA, it is noticeable that welding voltage and the voltage-speed interaction significantly affect both tensile and penetration depth. The developed empirical model to predict tensile strength and penetration depth can yield nearly accurate results, where the percentage error is below 10%, within the range of design environment