Optimisation of Metal Active Gas Welding on Mild Steel Using Response Surface Methodology

The widespread use of metal manufacturing in the modern world is aided by Metal Active Gas (MAG) welding, which is considered both efficient and versatile and can be included in the automation process. The current study is an optimization exercise dealing with MAG welding of mild steel to determine the influence of four prominent process parameters, namely, welding speed, welding current, welding voltage, and wire feed rate, upon two key process responses, namely, joint penetration and percentage defect. The empirical model was obtained using a Central Composite Design (CCD) method of the Response Surface Methodology (RSM) in order to establish the best settings of various parameters. The ANOVA and the results of the regression analysis showed that the current and the wire feed rate are the key factors that have a substantial impact on joint penetration, whereas the percentage of defects is heavily dependent on the voltage and the feed rate. High current and low wire feed rate yielded maximum joint penetration, and low weld defects were found at mid-range current, the voltage application, and weld speed. The statistical accuracy of the models developed was high, with R2 values of 97.44% for joint penetration and 96.32% for defects. The results included great information that may be used in enhancing the quality of welds, process stability, and efficiency, and it has considerable implications for industries that depend on well-performing welded structures.