Double pulse gas metal arc welding process parameter optimization and weld performance analysis based on response surface method

Double pulse gas metal arc welding (DP-GMAW) is a low-frequency modulated high-frequency pulse welding, which can fully stir the molten pool, and improve the forming and performance of the weld. In this study, a mathematical model was developed using the response surface method (RSM) with three main process parameters (welding current, peak-to-base ratio, welding speed) as input values with three key geometric characteristics parameters, and the mechanical properties of the resulting welds were investigated. The results showed that the parameter model developed in this study had less error and could optimize the process parameters better; the optimal process parameters (welding current, peak-to-base ratio, welding speed) were 160 A, 39.93%, and 83.11 cm min-1, respectively. The improved welding parameters result in better mechanical properties and better weld profile, and more stable welding process. As a result, this experiment provides a new perspective for process parameter optimization and mechanical properties research for weld manufacturing.