Influence of SMAW Welding Process Parameters on Hardness and Microstructure of AISI 1050 Steel

This study evaluates the impact of SMAW welding process parameters on AISI 1050 steel, focusing on variations in welding current, cooling method, and capping on weld hardness and microstructure. Brinell hardness test results indicate that the cooling method has the greatest influence (55.02%) on hardness variation, followed by welding current (24.57%) and capping (9.57%). The optimal parameters are 2 capping with 100A current and air cooling, which result in the highest hardness (222 HRB), while the lowest hardness is observed with 2 capping, 80A current, and oil cooling (190 HRB). Microstructural analysis shows that the combination of 2 capping with 80A current and oil cooling yields a balanced microstructure with minimal defects, whereas 120A current and air cooling cause microstructural instability and increased defects. This study highlights the importance of controlling process parameters for achieving high-quality welds.