Experimental investigations and optimization of weld bead characteristics during submerged arc welding using recycled steel slag as a flux.

A novel methodology has been established which allows to recycle steel slag as a suitable flux for submerged arc welding. The flux produced using waste slag as a raw material has been applied to deposit beads on plates. The bead geometry is dependent on welding parameters; hence optimization of parameters is essential. In this cut throat competition, researchers are striving to minimize the cost of experimentation using various experimental and optimization techniques to reduce number of experiments for save time, money, and resources. In this article various techniques have been explored for better optimized results. The welding parameters have been optimized to obtain desired bead geometry using various optimization techniques such as genetic and teaching–learning-based optimization algorithm, and desirability. It was observed that the genetic algorithm technique provides better results having a minimum error of penetration, bead width, and reinforcement (i.e. 1.12%, 1.83%, and 2.46%, respectively), as compared with other techniques applied. It is further observed that flux manufactured from waste slag is capable to produce desired bead profile which is similar with that of the fresh flux. Recycled slag is capable to produce optimum bead geometry having maximum penetration of 11.52 mm, bead width 20.73 mm, and reinforcement 3.24 mm. [ABSTRACT FROM AUTHOR]