Informatics and Engineering Systems Faculty Publications and Presentations

Document Type

Article

Publication Date

5-1-2025

Abstract

This study investigated the control of porosity during gas metal arc welding with pulsed arc (GMAW-P) of complex-phase 780 (CP780) galvanized steel. Due to the Zn coating on this type of steel, porosity forms during welding as a result of Zn vaporization. The objective was to optimize the welding parameters to minimize porosity with a design of experiments using an L9 orthogonal array to analyze the effects of peak current (Ip), pulse time (tp), and pulse frequency (f) in high-speed welding conditions. The results showed that porosity was significantly reduced with a peak current of 313 A, a frequency of 10 Hz, and a pulse time of 10 ms, achieving ~0% porosity in the validation welding trials. A microstructural analysis identified allotriomorphic ferrite, Widmanstätten ferrite, acicular ferrite, bainite, and martensite in the heat-affected zone (HAZ). A predictive model to anticipate the percentage of porosity with an R2 of 99.97% was developed, and an ANOVA determined the peak current as the most critical factor in porosity formation.

Comments

© 2025 by the authors. Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/).

Publication Title

Metals

DOI

10.3390/met15050513

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