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In this study, aluminum alloy sheets were welded on bead-on-plate using AC type TIG welding machine. Penetration depth and bead width were selected as quality factors of weld bead. Welding conditions were designed with BBD(Box-Benhken Design) method in which the input variables were welding current, arc length and travel speed. TIG welding was done on A6061 alloy sheet for the welding conditions selected by DOE at Ar shielding. The second-order regression equation was obtained using the bead shape measured from TIG welded samples. Verification test was done at the optimum welding condition determined by the surface response diagram derived from the regression equation. The optimum welding condition was welding current 110A, arc length 1.4mm and travel speed 9.6mm/s. The penetration depth and the bead width formed at the predicted optimum welding condition were 1.97±0.010mm and 4.65±0.051mm. From the result, the regression equation matched with real TIG welding in accuracy 98.5% and 96.8% for penetration depth and bead width respectively.

A Study for TIG Welding Optimization on Bead Shape of A6061 Alloy Sheet using DOE