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<p>In the present research, optimizing the MIG welding parameters for Inconel 825 is investigated by Taguchi L8 Orthogonal Array method coupled with statistical regression analysis and microstructural analysis. The novelty of this work is the combination of statistical process optimization and the assessment of the welding process using the Scanning Electron Microscopy (SEM) technique to draw a relationship between the welding process parameters, weld bead geometry and Heat-Affected Zone (HAZ) characteristics. Wire Feed Speed, Welding Voltage, and Travel Speed were systematically investigated to understand the effects of these parameters on the quality of the welds, produced by the MIG-based Wire Arc Additive Manufacturing (WAAM) and cladding processes, for further optimizing the processes for better weld performance. A Master MIG welding station was utilized wherein Inconel 825 was the base and filler. Key process indicators – Wire Feed Rate (3–11.96&#xa0;m/min), Welding Voltage (18–26&#xa0;V), Travel Speed (300–842&#xa0;mm/min) and Nozzle to plate distance (4.08–5.79&#xa0;mm) – were theoretically computed with Taguchi L8 Orthogonal Array. A benchmark assessment was carried out in comparison to the standard parameter configuration. The Depth of Weld Bead and Heat-Affected Zone were among the Response Outcomes that were evaluated. The parameters were optimized to obtain the best weld quality in terms of the average depth of the weld bead (2.2&#xa0;mm, SD: 0.25&#xa0;mm) and the average width of HAZ (3.0&#xa0;mm, SD: 0.35&#xa0;mm). Wire Feed Rate and Welding Voltage were determined as the significant factors by statistical analysis. It was observed that our main variables in the study were Wire Feed Rate and Welding Voltage, and this was the same case for the regression models. The work is focused on obtaining optimized MIG welding parameters to achieve better weld penetration and controlled formation of the Heat-Affected Zone (HAZ) with Inconel 825 by applying statistical regression analysis and the Taguchi L8 Orthogonal Array (OA) to the experimental design. This study particularly emphasizes the simultaneous effect of Wire Feed Speed, Welding Voltage and Travel Speed on weld bead geometry and thermal characteristics, offering an efficient experimental approach to improve weld quality for high-performance industrial applications.</p>

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Optimization of MIG welding parameters for enhanced weld bead geometry and heat-affected zone in inconel 825 using taguchi design and regression analysis

  • 期刊论文

  • 发表日期：

    2026年7月10日

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  • C M DINESH,
  • A. V. Balan,
  • S. P. Sankar,
  • C. Senthil Kumar,
  • S. Rahul

摘要

In the present research, optimizing the MIG welding parameters for Inconel 825 is investigated by Taguchi L8 Orthogonal Array method coupled with statistical regression analysis and microstructural analysis. The novelty of this work is the combination of statistical process optimization and the assessment of the welding process using the Scanning Electron Microscopy (SEM) technique to draw a relationship between the welding process parameters, weld bead geometry and Heat-Affected Zone (HAZ) characteristics. Wire Feed Speed, Welding Voltage, and Travel Speed were systematically investigated to understand the effects of these parameters on the quality of the welds, produced by the MIG-based Wire Arc Additive Manufacturing (WAAM) and cladding processes, for further optimizing the processes for better weld performance. A Master MIG welding station was utilized wherein Inconel 825 was the base and filler. Key process indicators – Wire Feed Rate (3–11.96 m/min), Welding Voltage (18–26 V), Travel Speed (300–842 mm/min) and Nozzle to plate distance (4.08–5.79 mm) – were theoretically computed with Taguchi L8 Orthogonal Array. A benchmark assessment was carried out in comparison to the standard parameter configuration. The Depth of Weld Bead and Heat-Affected Zone were among the Response Outcomes that were evaluated. The parameters were optimized to obtain the best weld quality in terms of the average depth of the weld bead (2.2 mm, SD: 0.25 mm) and the average width of HAZ (3.0 mm, SD: 0.35 mm). Wire Feed Rate and Welding Voltage were determined as the significant factors by statistical analysis. It was observed that our main variables in the study were Wire Feed Rate and Welding Voltage, and this was the same case for the regression models. The work is focused on obtaining optimized MIG welding parameters to achieve better weld penetration and controlled formation of the Heat-Affected Zone (HAZ) with Inconel 825 by applying statistical regression analysis and the Taguchi L8 Orthogonal Array (OA) to the experimental design. This study particularly emphasizes the simultaneous effect of Wire Feed Speed, Welding Voltage and Travel Speed on weld bead geometry and thermal characteristics, offering an efficient experimental approach to improve weld quality for high-performance industrial applications.