Optimization of flux cored arc welding parameters to minimize the dilution percentage of AISI 316L stainless steel cladding on mild steel

The main objective of this work is to develop the cladding of austenitic stainless-steel wire on mild steel and to develop a mathematical model for predicting the dilution percentage. Flux cored arc welding (FCAW) was used to deposit the clad of AISI 316L on mild steel. The cladding was carried out by considering the five main process parameters of FCAW such as voltage, wire feed, welding speed and distance between nozzle and plate. The design expert software was utilized for making the experimental matrix. The Response Surface Methodology (RSM) was used to optimize the FCAW parameters for minimizing the dilution. The response surfaces were generated for analyzing the direct effect and interaction effect of FCAW parameters on dilution percentage. The mathematical model was established for predicting the dilution percentage in cladding and was validated using analysis of variance (ANOVA). The FCAW parameters were optimized using response surface methodology (RSM) to minimize the dilution percentage. The AISI 316L cladding deposited on mild steel using welding voltage of 31 V, wire feed rate of 10 m/min, welding speed of 0.25 m/min, distance between nozzle and plate of 18 mm and electrode angel of 14° showed lower dilution rate of 6.4%. The mathematical model accurately predicted the dilution percentage with less than 5% error. The prediction model was validated using ANOVA showing insignificant lack of fit. Based on the experimental analysis, the welding speed was found to be the most significant parameter that controls the dilution percentage.