Influence of GMAW Operating Parameters on the Metallurgical Properties of AISI 304 Steel Welds

Eduardo Pereira da Silva; Allan Barbosa da Silva; Carlos Alberto Carvalho Castro

doi:10.36674/mythos.v17i2.1032

Authors

Eduardo Pereira da Silva Federal Center for Technological Education of Minas Gerais – CEFETMG
Allan Barbosa da Silva Federal University of Itajubá - UNIFEI
Carlos Alberto Carvalho Castro Federal Center for Technological Education of Minas Gerais – CEFETMG

DOI:

https://doi.org/10.36674/mythos.v17i2.1032

Keywords:

Welding. Microstructure. Sensitization. Stainless Steel.

Abstract

This study investigates the influence of Gas Metal Arc Welding (GMAW) parameters, current, voltage, and travel speed, on the penetration and quality of welds in AISI 304 stainless steel. A full factorial Design of Experiments (DoE) was employed to assess both the individual and interactive effects of these parameters. The results demonstrated that welding current is directly proportional to penetration, whereas travel speed exhibits an inverse relationship, reflecting their combined control over heat input. Voltage, in turn, presented a non-linear effect, with a marked increase in penetration observed specifically at 25 V. The interaction plots further revealed that the combination of high current and low travel speed maximizes penetration, corroborating fundamental arc welding principles. Moreover, a synergistic effect was identified between intermediate current levels (116–120 A) and a voltage of 25 V, which substantially enhanced penetration. These findings highlight that weld bead geometry and metallurgical properties are direct consequences of the thermal cycle imposed by the selected process parameters. Consequently, effective optimization requires an integrated approach that considers not only the isolated effects but also the interactions among current, voltage, and travel speed, thereby ensuring the geometrical control, metallurgical integrity, and overall performance of the welded joint.

Author Biographies

Eduardo Pereira da Silva, Federal Center for Technological Education of Minas Gerais – CEFETMG

Doctor in Mechanical Engineering from UNIFEI, with an emphasis on Design, Materials, and Processes, working primarily in the fields of technological innovations in manufacturing processes, such as welding, microstructure, mechanical properties, metallurgy, and CNC machining. He has professional experience in the metal-mechanical industry, with an emphasis on general fundamentals of machine design since 2002, having worked in machining, boilerwork, and mechanical maintenance. Since 2009, he has served as a mechanical laboratory technician at CEFET-MG, where he coordinated the laboratories of the Department of Mechatronics (DMCVG) at the Varginha campus in 2015 and 2016, and has participated in several research and technological innovation projects. He is currently a member of the editorial board of the journal Mythos and works as a researcher in various research groups, including GPIT (Research and Technological Innovation Group – CEFET-MG), the Manufacturing Group (UNIFEI), and the Research Group in Automation and Robotics (CEFET-MG). His primary research area involves the welding of special alloys, such as titanium, aluminum, stainless steels, among other, with a focus on processes and the improvement of mechanical and microstructural properties. He also co-supervises undergraduate research and capstone projects, and provides training for companies in the region.

Allan Barbosa da Silva, Federal University of Itajubá - UNIFEI

Master’s degree in Mechanical Engineering from the Federal University of Itajubá (UNIFEI), with a focus on Design, Materials, and Processes. Graduated in Mechanical Engineering from the University Centre of Southern Minas (UNIS). During his undergraduate studies, he carried out a Scientific Initiation Project entitled “Study of the influence of operational parameters of the GMAW process on the metallurgical properties of the welded region of AISI 304 stainless steel” (FAPEMIG PIBIT 2012). He also holds a technical qualification in Mechatronics from CEFET-MG, Varginha Campus, where he began his academic and research activities as a teaching assistant and scientific initiation student in the field of welding, having presented his work abroad (Portugal) at a scientific conference. He has professional experience in Industrial and Building Maintenance, working directly in the areas of Maintenance Planning and Control (MPC) and Facilities Management, where he carried out various activities related to planning corrective, preventive, and predictive maintenance; drafting and managing procedures; performance indicators (KPIs); investments; problem-solving; inventory management; and continuous improvement, among others. He has also worked in Process Engineering (Assembly) and is currently dedicated to the field of Welding Technology.

Carlos Alberto Carvalho Castro, Federal Center for Technological Education of Minas Gerais – CEFETMG

Full Professor at CEFET-MG. He holds a degree in Mechanical Engineering from the State University of Minas Gerais – UEMG (1997), a Master’s degree in Nuclear Engineering from the Military Institute of Engineering – IME (2000), and a PhD from the Federal University of Minas Gerais – UFMG (2007). His research focuses on innovative technological processes, including welding processes, microstructure, mechanical properties, materials fatigue, metallurgy, testing, design, new damage models in metals and non-metals (geosynthetics), clean energy generation, environment, and radiation. He has coordinated and participated in research projects funded by Brazilian research agencies (CNPq, FAPEMIG, and PROPESQ). He serves as an ad hoc Researcher and Consultant for CNPq and FAPEMIG. He is a faculty member at the Federal Centre for Technological Education of Minas Gerais and a professor in the Master’s Programme in Materials Engineering. He has also acted as a visiting professor in the Master’s Programme in Civil Engineering, teaching the subject Solid Mechanics of Materials. He is a reviewer for several conferences and journals, leader of the Research Group on Technological Innovation (GIPT), and a member of two additional research groups. He has co-supervised Master’s and Doctoral students and currently divides his professional activities among teaching, research, and outreach. He has authored numerous publications both in Brazil and abroad.

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