Experimental Analysis of Electrode Size on the Strength of the Weld Joint Using 4.00 mm Electrode

Authors:

Gopal Vanga¹, G. Kedarnath²

¹Associate Professor, Department of Mechanical Engineering, Guru Nanak Institutions Technical Campus, Hyderabad, India

²Assistant Professor Department of Mechanical Engineering, Guru Nanak Institutions Technical Campus, Hyderabad, India

Abstract - Welding plays a major role in fabrication and manufacturing industries where the strength and quality of weld joints directly affect structural performance. This research investigates the effect of electrode size on the strength of welded joints using a 4.00 mm electrode in arc welding. Mild steel plates were prepared and joined using Shielded Metal Arc Welding (SMAW). Experimental analysis was performed through Rockwell hardness testing, dye penetrant testing, and tensile testing to evaluate weld quality, hardness, and tensile strength. The study observed that welding current significantly influences weld properties. Higher current reduced hardness and tensile strength, while controlled current improved joint integrity and weld quality. Surface defects such as undercut and incomplete fusion were identified through dye penetrant inspection. The results demonstrate the importance of selecting appropriate welding parameters and electrode size for achieving stronger and more reliable weld joints.

Key Words:  Arc Welding, Electrode Size, Tensile Strength, Dye Penetration Test, Hardness Test, Mild Steel, SMAW.