Parametric Optimization of Gas Metal Arc Welding Process Parameters
DOI:
https://doi.org/10.46604/aiti.2026.16345Keywords:
gas metal arc welding, low-carbon steel, finite element model, response surface methodology, welding parameters optimizationAbstract
The gas metal arc welding (GMAW) parameters for a homogeneous low-carbon steel butt-welded plate are optimized using a systematic integrated model. This study aims to create a thermo-mechanical finite element model to predict the weld bead geometry during GMAW. The numerical model incorporates the Goldak double-ellipsoid model, temperature-dependent material properties, and coupled thermo-mechanical finite element analysis. The model is validated against published experimental data and used for a parametric study. Response surface methodology is then applied to develop a statistical model for optimizing GMAW parameters while maintaining geometric constraints on fusion width and cumulative heat. The validated computational model exhibits exceptional precision in reconstructing the weld bead geometry, with prediction errors below 5% in penetration depth and fusion width. The optimized parameters are: 261.5 A of current, 25.8 V of voltage, and 850 mm/min of travel velocity with 2.45 mm penetration depth and 9.98 mm fusion width.
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