Multi-performance optimization of gas metal arc welding operation in terms of energy saving and quality criteria

Most published works related to gas metal arc welding processes focus on quality criteria, while energy consumed has not been considered. In this study, key parameters of the gas metal arc welding (GMAW) operation of the AISI 1045 steel, including the current (I), voltage (V), flow rate (F), and nozzle stand-off distance (D) are optimized to minimize energy consumed (EC) and enhance the ultimate tensile strength (TS) as well as elongation (EL). The radial basis function network (RBFN) is employed to propose GMAW responses. The Entropy method, modified grey wolf optimizer (MGWO), and Multi-Attributive Border Approximation Area Comparison (MABAC) were utilized to compute the weights, generate feasible solutions, and determine the best optimality. As a result, the optimal I, V, F, and D were 137 A, 23 V, 12 L/min, and 12 mm, respectively. The EC was reduced by 5.8, while the TS and EL were improved by 3.3 and 20.7, respectively, at the optimality. The EC and EL models were primarily affected by the I, V, F, and D, respectively. The TS model was mainly influenced by the I, D, F, and V, respectively. The RBFN-MGWO could be employed to present non-linear data and achieve better optimal results, as compared to the traditional approach. The obtained outcomes could be used to produce high-quality welds with minimizing environmental impacts. © 2024 Informa UK Limited, trading as Taylor & Francis Group.