Analysis of heat affected zone and correlated influences in bypass process GMAW of steel alloy 410

From the early 19th century the Gas Metal Arc Weldingapplications have expanded from steel fabrications to other industrial sectors like construction, mechanical and car manufacturing etc. One of the problems associated with GMAW is the overheating of the base metal. Overheating causes a lot of damage to the weld components and therefore they distort the shape and size of the base metal and cause a lot of welding issues. To counter this issue a novel welding process called as the bypass process is being developed in order to sort out the heating problems of the conventional welding process at its Heat affected zone (HAZ) area. This paperpresents ananalysis on the bypass process to obtain better-quality welds with a lesser heat input. Experiments are being conducted on the samples made up of AMS5504. The bypass process can reduce HAZ size without decreasing the welding productivity. Despiteincrease in the indentation hardness in the HAZ, quality of the weld can beimproved. It is shown that the HAZ area is proportional to the heat input both in bypass welding process as well as the conventionalwelding.