Enhancing Metal Active Gas Welding Parameters through Taguchi-Six Sigma Framework for Improved Quality and Performance
DOI:
https://doi.org/10.64229/gymajy12Keywords:
Process optimization, Taguchi-based six sigma, Mechanical properties, Ultimate tensile strength, Impact resistanceAbstract
Optimizing Metal active gas (MAG) welding parameters is vital for enhancing weld quality, mechanical performance, and overall manufacturing efficiency. This study introduces an integrated optimization framework that combines Taguchi’s design of experiments (DOE) with the statistical rigor of six sigma to identify optimal welding conditions while minimizing process variability. The framework was applied to Steel 37, a widely used structural material, focusing on key process variables: wire diameter, feed rate, welding voltage, and gas flow rate. These parameters and their interactions were systematically analyzed for their influence on critical mechanical properties, including ultimate tensile strength (UTS), weld hardness, and impact resistance. To support optimization, a regression-based predictive model was developed to provide data-driven insights for selecting optimal process settings. The proposed model serves as a practical industrial tool to reduce variability, enhance weld integrity, and improve productivity in real-world manufacturing environments. The findings demonstrate the potential of integrating Taguchi’s robust design and six sigma methodologies to develop high-performance, cost-effective, and sustainable welding processes. By leveraging structured experimentation, statistical modeling, and systematic analysis, this framework offers a deeper understanding of parameter interrelationships and supports the advancement of reliable and efficient manufacturing operations.
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Copyright (c) 2026 Nadia Hamzawy, Attia Hussien Gomaa (Author)
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