Effect of arc length trim and adaptive pulsed-MIG process parameters on bead profile of stainless steel with synergic power source Sanjib Jaypuria a , Trupti Ranjan Mahapatra b,⇑ , Sanjukta Sahoo c , Omkar Jaypuria d a Mechanical Engineering Department, Indian Institute of Technology Kharagpur, Kharagpur 721302, India b Department of Production Engineering, Veer Surendra Sai University of Technology (VSSUT), Burla 768018, India c Department of Civil Engineering, KIIT Polytechnique, KIIT (deemed to be University), Bhubaneswar, Odisha 751024, India d Department of Civil Engineering, College of Engineering and Technology, Bhubaneswar 721302, India article info Article history: Received 26 November 2019 Accepted 3 January 2020 Available online xxxx Keywords: Trim Pulse-MIG Bead profile Dilution Pulse waveform Synergic power Arc length abstract The real-world application of pulse-MIG process is increasing day by day due to the adaptive nature of process parameters along with synergic power source and associated spray metal transfer. In this study, the effect of process parameters on weld bead profile is evaluated in adaptive pulse-MIG welded stainless steel plate. The responses considered in this study are penetration depth and percentage dilution, which are considered to be significant in deciding strength and weld integrity. The regression model between input-output has been developed and validated through statistical tools. A high level of wire feed speed and trim along with low level of welding speed and contact tube to work distance are found to be the optimized way to maximize percentage dilution in pulse-MIG welding. In this manner, low levels of trim, welding speed and contact tube to work distance are seemed to be the possible combination to achieve deeper penetration along with the high level of wire feed speed. In addition to this, arc length trim, which is an inbuilt process parameter in synergic pulse-MIG machine has been discussed and studied. Trim con- trols the arc length and voltage automatically when a set of input conditions are specified. A detailed dis- cussion on influence of trim on bead parameters has been discussed. It is seen that penetration depth, reinforcement height has shown clear reduction tendency with increasing arc length trim. The observed variation of bead width is very nominal variation with respect to trim and percentage dilution has shown both decreasing and growing trend with increasing trim. Ó 2020 Elsevier Ltd. All rights reserved. Selection and of the scientific committee of the 10th International Conference of Materials Processing and Characterization. 1. Introduction Gas metal arc welding (GMAW) or metal inert gas (MIG) weld- ing is a promising fusion welding process that has been used in many industries due to ease of fabricating all kinds of metallic materials with less capital investment. The MIG welding using a pulsed current waveform generally referred to as pulse-MIG weld- ing, which an upgraded version of MIG with precise and controlled metal transfer during welding [1]. In addition to this, pulse-MIG comes with advantages like low spatters, high efficiency and good penetration ability when it is compared with conventional MIG. The pulse mode of waveform introduces a few other welding parameters such as base and peak currents, current duration in the welding process, which makes the process complex for use [2]. The advanced welding process is worked by using a low level of base current to maintain the arc and a high level of peak current for melting of electrode. In addition to this, other parameters like frequency and base and peak current duration comes into play for achieving proper metal transfer behavior in pulse-MIG [3]. Therefore, many efforts have been made to model the input- output behavior and to study the effect of process parameters on joint quality with desired metal transfer behavior [4,5]. Although a desired metal transfer behavior is obtained through pulse-MIG, there is significant difference in arc behavior and metal transfer dynamics for the welded joints with nearly equal process variables using different welding equipment [6,7]. The difference in the response values with different machines are mostly due to arc-power source interaction, which is directly related to dynamic response of the used power source. Therefore, many weld equip- https://doi.org/10.1016/j.matpr.2020.01.027 2214-7853/Ó 2020 Elsevier Ltd. All rights reserved. Selection and of the scientific committee of the 10th International Conference of Materials Processing and Characterization. ⇑ Corresponding author. E-mail address: trmahapatra_pe@vssut.ac.in (T.R. Mahapatra). Materials Today: Proceedings xxx (xxxx) xxx Contents lists available at ScienceDirect Materials Today: Proceedings journal homepage: www.elsevier.com/locate/matpr Please cite this article as: S. Jaypuria, T. R. Mahapatra, S. Sahoo et al., Effect of arc length trim and adaptive pulsed-MIG process parameters on bead profile of stainless steel with synergic power source, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.01.027