Optimization of the factor level in the carbon steel welding process using a robotic arm

Abstract

This study aimed to identify optimal factors for designing welding experiments using the robotic arm for carbon steel. Utilizing the Box Behnken Design method, 30 experiments focused on three main factors: electric current, wire feed speed, and welding speed. The materials used included carbon steel (50 mm wide, 150 mm long, 4.5 mm thick), MIG welding wire (1.2 mm size), and 100% CO2 as the shielding gas. A Toyo Capacity 60 Tons (Model 60T) pressure testing machine was employed. The welding was performed using a flat butt connection. Results showed that the optimal settings were an electric current of 110 amperes, wire feed speed of 2.65 m/min, and welding speed of 5 mm/s. These parameters yielded a weld strength of 5,000 kg/cm² and produced a welding line that met the acceptable standards.