Indian Journal of Science and Technology

Abstract

Objectives: ANSYS software has been used to predict temperature, stress, and heat flux distributions for dissimilar welding of MONEL 400 and AISI 304. Methods/Statistical Analysis: A total of twenty seven experiments have been performed for welding of MONEL 400 alloy and AISI 304 by using TIG welding process to find out the best possible welding parameters. The experiments conducted have been divided into three groups. In the first stage, second stage and third stage of experiments was conducted to study the welding process with AISI 304 filler rod, AISI 316 filler rod and MONEL 400 filler rod respectively. Findings: The developed stress is smaller at 350 amp current, AISI 304 filler rod, and 3.6 mm/s welding speed, which is noted as 0.31 × 10-15 MPa. The optimum TIG welding parameter for stress was obtained as 150 amp current, AISI 304 filler rod, and 3.6 mm/s welding speed. The mean value of generated temperature is higher at 350 amp current, AISI 316 filler rod, and 5.5 mm/s welding speed, which is observed as 75671°C. The optimum TIG welding parameters are 350 amp input current, AISI 316 filler electrode, and 3.6 mm/s welding speed for developed temperature. The optimum TIG welding parameter for heat flux was obtained as 350 amp current, MONEL 400 filler rod, and 5.5 mm/s welding speed. Application/Improvements: Dissimilar metal joints between MONEL 400 and AISI 304 are widely used in various applications fields like heat exchanger, chemical processing equipment etc.

Keywords: AISI 304, ANSYS Software, Dissimilar Metal Weld, MONEL 400 Alloy, TIG welding, Welding Simulation