Effect of Welding Sequence in Angular Distortion on Butt Joint GMAW Process
Round 1
Reviewer 1 Report
In this manuscript, the authors analyzed the impact of three welding sequences of GMAW process on angular distortion in butt-joints. This welding process is performed on S235 steel plates. Metrological assessment has been used to make the comparison between the results of the three welding sequences.
In reviewer's opinion, the paper can be recommended for publication in Journal of applied science after addressing minor revision considering the following remarks:
- At the end of the introductory section it is better if the authors add an introduction of their work.
- In section 3.2, do both plates have chamfers on the welded edges or not? And the cutting process used to prepare these plates in not also specified in the text.
- What is the reason to make the grid on the plates before the test?
- The choice of the grid element shape and dimension is not explained on the text.
- Authors need to explain the meaning of F-value and p-value in table 6.
- Using the same welding sequence, three tests are performed. If there is no change in the process parameters, why the difference between the values exist?
- Table 8. The unit of displacement is the mm? It seems that the deformation that occurs during this welding process is very large, which means that the process is not efficient in this type of assembly.
- Figure 12 SM instead of ST, I think
- In term of displacement or distortion it is clear that SM sequence is better than the two other sequences but what about the homogeneity and the quality of the welding line?
- In the conclusion section it is recommended to highlight the novelty of the current research compared to what it is done in the literature.
Author Response
The authors would like to acknowledge the careful revision done by the Reviewer, as well as his/her precious suggestions and comments. Also, we would like to thank the Editor for the opportunity that was given to us regarding the improvement of the original version of the manuscript (MS) and the further resubmission of the improved MS. Hence, we hope that this new version of the MS is worth publishing in the Applied Sciences.
In this manuscript, the authors analyzed the impact of three welding sequences of GMAW process on angular distortion in butt-joints. This welding process is performed on S235 steel plates. Metrological assessment has been used to make the comparison between the results of the three welding sequences.
In reviewer's opinion, the paper can be recommended for publication in Journal of applied science after addressing minor revision considering the following remarks:
- At the end of the introductory section, it is better if the authors add an introduction of their work.
Answer: The authors thanks to the comment of the reviewer. We added in lines 56-58 an introduction about our work. This information is highlighted in yellow.
- In section 3.2, do both plates have chamfers on the welded edges or not? And the cutting process used to prepare these plates in not also specified in the text.
Answer: Thank you very much for your comment we agree that is very important to add this information. Indeed, it was a butt joint with square borders because the plate thickness was only 3 mm. This information and the border preparation are described in lines 190-193 (we highlighted these lines).
- What is the reason to make the grid on the plates before the test?
Answer: Thank you very much for your question. The plates have some irregularities due to the manufacturing process, storage, and cutting process. So, we did a control measurement before the welding process, for this reason, we drew the grids before the welding and use the points where occurred the crossing lines as references. After welding the plates, we measured the same points and subtracted the values measured before the welding to obtain the correct value of distortion.
- The choice of the grid element shape and dimension is not explained on the text.
Answer: Thanks for your important question. The reason to draw the grid was to have reference points that we could use to measure with the HandyPROBE equipment the displacement (distortions) caused by the welding process.
- Authors need to explain the meaning of F-value and p-value in table 6.
Answer: We are agreeing with your comment, effectively we forgot to indicate this information. We add the meaning of these parameters in lines 265-267, which are highlighted.
- Using the same welding sequence, three tests are performed. If there is no change in the process parameters, why does the difference between the values exist?
Answer: Thank you for your comment. We did three tests to analyze the process repeatability. As with any manufacturing process, we have environmental factors (room temperature, equipment clearances, among others) that can influence the results. In our work, the used equipment to fix and move the welding torch was made by us, so we believe that could influence the obtained results.
- Table 8. The unit of displacement is the mm? It seems that the deformation that occurs during this welding process is very large, which means that the process is not efficient in this type of assembly.
Answer: Added, line 375, “To verify whether the differences in displacements between the sequences are statistically significant, a one-way ANOVA was performed with the default significance level of 95%. The sum of vertical displacements was performed and became a single variable for each sample (Table 8). Prior to performing ANOVA, Levene's test was applied to sample data to verify the homogeneity of variances. The test resulted in the null hypothesis being true in order to conclude that the variances are homogeneous and that it is possible to use the parametric ANOVA test for this data sampling. All the vertical displacements measured were summed and transformed in one only variable for each sample.”
- Figure 12 SM instead of ST, I think.
Answer: Thank you very much for your observation. We corrected the mistake.
- In term of displacement or distortion it is clear that SM sequence is better than the two other sequences but what about the homogeneity and the quality of the welding line?
Answer: Thanks for your interesting comment. Before we begin the presented tests, we did some previous tests to obtain a good-quality welding joint. At the end of each test set, we analyzed the quality of the welding joints, and we verified the quality maintained after all experimental tests. We didn’t show any significant differences.
Reviewer 2 Report
In this work, authors studied the effect of some welding parameters and sequences on the distortion defect.
The experiment was clearly described but results are limited. Also, there are several language mistakes in the manuscript and its quality needs a considerable improvement. An English editing of the manuscript is recommended. In the following, you can find some points that should be addressed:
1/ Line 32-33: “the main reasons for that choice are because their good 32 degree of reliability and high production velocity”: please reformulate this expression (do not use reasons and because at the same time).
2/ Line 35: “ is the most applied”: please consider :”is one of the most applied”
3/ Line 37: “ and good quality welds”: please consider “ and good quality of welds”
4/ Line 41-42 : “ During the welding process, usually occur non-uniform expansions and contractions”
Please consider : “ During 41 the welding process, usually non-uniform expansions and contractions occur”
5/ Line 46-47: “while in the weld bead is generated high values of tensile stresses”. Please consider: “while high values of tensile stresses are generated in the weld bead”
6/ Line 51: please replace the word “quantity” by “values”
7/ Line 62-63 : “It means that residual stresses do not result in deformation.” Are you sure? Please clarify this statement.
8/ Line 71-72: “The most pronounced type of distortion in butt-welded plates is the angular distortion and it is also its greatest problem”. Please reformulate this sentence
9/ Line 84: “Many studies to investigate the influences…”. Please consider “Many studies investigated the influences…”
10/ Line 92-93: “can be directly 92 proportional influenced by the voltage…”. Please reformulate this expression.
11/ Line 96: “based in”. Please consider “based on”
12/ Line 104: “it gradually reduces towards to the starting…”. Please consider “it is gradually reduced to the starting …”
13/ Line 110: “when the time gap between the passes increase”. Please consider “when the time gap between the passes increases”
14/ Line 177: the cited dimensions are different from that given in figure 5. Please correct that.
15/ Line 200-201:” to guarantee that imperfections of the materials and human, 200 or machine failure would not interfere during the execution of the experiment”. Please reformulate the sentence.
16/ Line 206: “Figure 5 shows the sequences”. Not figure 5. Please correct that.
Comments for author File: 
Comments.pdf
Author Response
The authors would like to acknowledge the careful revision done by the Reviewer, as well as his/her precious suggestions and comments. Also, we would like to thank the Editor for the opportunity that was given to us regarding the improvement of the original version of the manuscript (MS) and the further resubmission of the improved MS. Hence, we hope that this new version of the MS is worth publishing in the Applied Sciences.
In this work, authors studied the effect of some welding parameters and sequences on the distortion defect.
The experiment was clearly described but results are limited. Also, there are several language mistakes in the manuscript and its quality needs a considerable improvement. An English editing of the manuscript is recommended. In the following, you can find some points that should be addressed:
- Line 32-33: “the main reasons for that choice are because their good 32 degree of reliability and high production velocity”: please reformulate this expression (do not use reasons and because at the same time).
Answer: Thank you very much for your suggestion. We corrected and highlighted in MS.
- Line 35: “ is the most applied”: please consider :”is one of the most applied”
Answer: Thank you very much for your suggestion. We corrected and highlighted in MS
- Line 37: “ and good quality welds”: please consider “ and good quality of welds”
Answer: Thank you very much for your suggestion. We corrected and highlighted in MS
- Line 41-42: “During the welding process, usually occur non-uniform expansions and contractions”. Please consider: “During 41 the welding process, usually non-uniform expansions and contractions occur”
Answer: Thank you for the suggestion. We corrected it with “During the welding processes (…)”. The correction is highlighted in MS.
- Line 46-47: “while in the weld bead is generated high values of tensile stresses”. Please consider: “while high values of tensile stresses are generated in the weld bead”
Answer: Thank you very much for your suggestion. We corrected and highlighted in MS
- Line 51: please replace the word “quantity” by “values”
Answer: Thank you very much for your suggestion. We corrected and highlighted in MS
- Line 62-63 : “It means that residual stresses do not result in deformation.” Are you sure? Please clarify this statement.
Answer: Thank you very much for your suggestion. We corrected and highlighted in MS
- Line 71-72: “The most pronounced type of distortion in butt-welded plates is the angular distortion and it is also its greatest problem”. Please reformulate this sentence
Answer: Thanks, we reformulated the sentence.
- Line 84: “Many studies to investigate the influences…”. Please consider “Many studies investigated the influences…”
Answer: Thank you very much for your suggestion. We corrected and highlighted in MS
- Line 92-93: “can be directly 92 proportional influenced by the voltage…”. Please reformulate this expression.
Answer: Thank you very much for your suggestion. We corrected and highlighted in MS
- Line 96: “based in”. Please consider “based on”
Answer: Thank you very much for your suggestion. We corrected and highlighted in MS
- Line 104: “it gradually reduces towards to the starting…”. Please consider “it is gradually reduced to the starting …”
Answer: Thank you very much for your suggestion. We corrected and highlighted in MS
- Line 110: “when the time gap between the passes increase”. Please consider “when the time gap between the passes increases”
Answer: Thank you very much for your suggestion. We corrected and highlighted in MS
- Line 177: the cited dimensions are different from that given in figure 5. Please correct that.
Answer: Thanks for your observation. Indeed, we made a mistake, each plate has the following dimensions: 220 x 100 x 3 mm3.
- Line 200-201:” to guarantee that imperfections of the materials and human, 200 or machine failure would not interfere during the execution of the experiment”. Please reformulate the sentence.
Answer: Thank you very much for your suggestion. We corrected and highlighted in MS
- Line 206: “Figure 5 shows the sequences”. Not figure 5. Please correct that.
Answer: Thank you very much for your suggestion. We corrected and highlighted in MS
Author Response File: Author Response.pdf
Reviewer 3 Report
Dear Authors,
thank you very much for your work and your article. I really liked the idea. Unluckily I found out that after reading your article I was not any wiser. this might be due to my limited understanding of details in research of welding. I did not understand how you did your measurement, that is what kind of measurement with what accuracy you used. A drawing about butt joint welding would have been helpfull for those who are not in details for English words in the field of welding (the internet in the end gave the necessary details). I did not use the internet to acquire additional knowledge about your measurement tools. The might be commen knowledge, unluckily not for me.
it was difficult for me to understand your results. for example the graphs with the double layers (Fig. 10). how did you use the ANOVA? T-Test is a means for evaluating data which might have an overlayer of statistical offsets. you presented F- and p- values, based on what?
Your Tables 1-4 were irritating for me. may you please reconsider what you want to tell with them and how to deliver your message? Especially table 3 was bewildering for me.
I attached our file with coloured marks and some notes. the coloured marks are mostly concerend with language effects I stumbled across. the one or other remark is in the "remarks".
I really appreciate the work you did and the result you got. I am looking forward for your further results. If my remarks tend to be far fetched, I am not myself working in metall processing. so I might be too far away for a sponanous understanding of the details of your work. I apologize for any inconvenience.
Comments for author File: Comments.pdf
Author Response
The authors would like to acknowledge the careful revision done by the Reviewer, as well as his/her precious suggestions and comments. Also, we would like to thank the Editor for the opportunity that was given to us regarding the improvement of the original version of the manuscript (MS) and the further resubmission of the improved MS. Hence, we hope that this new version of the MS is worth publishing in the Applied Sciences.
Thank you very much for your work and your article. I really liked the idea. Unluckily I found out that after reading your article I was not any wiser. this might be due to my limited understanding of details in research of welding. I did not understand how you did your measurement, that is what kind of measurement with what accuracy you used. A drawing about butt joint welding would have been helpfull for those who are not in details for English words in the field of welding (the internet in the end gave the necessary details). I did not use the internet to acquire additional knowledge about your measurement tools. The might be common knowledge, unluckily not for me.
It was difficult for me to understand your results. for example the graphs with the double layers (Fig. 10). how did you use the ANOVA? T-Test is a means for evaluating data which might have an overlayer of statistical offsets. you presented F- and p- values, based on what?
Answer: Thank you very much for your useful questions. Figure 10 is a very common representation of the displacement field, so, the top layer showing, in 2D representation, and the bottom layer have the same information but is represented in 3D. For each method (SM, BM and SP) we did three repetitions, for this reason, we wanted, we evaluate statistically the obtained results. These statistical parameters are frequently used in the treatment of experimental data.
Your Tables 1-4 were irritating for me. may you please reconsider what you want to tell with them and how to deliver your message? Especially table 3 was bewildering for me.
Answer: Thanks for your comment. In these tables, we want to give information about the chemical composition and mechanical properties of the materials (base and addition material) used in this work. Table 1 presents the chemical composition of plate materials, Table 2 shows the chemical composition of the electrodes used to weld the samples, in Table 3 gives information about the mechanical properties of the electrodes (in the first column is indicate the product company reference and the ISO standard designation). Table 4 gives the range of use of the welding parameters for the electrode used in this work.
I attached our file with coloured marks and some notes. the coloured marks are mostly concerend with language effects I stumbled across. the one or other remark is in the "remarks".
Answer: Thank your suggestion. The colored marks with the language issues were corrected, and the remarks were verified.
I really appreciate the work you did and the result you got. I am looking forward for your further results. If my remarks tend to be far fetched, I am not myself working in metall processing. so I might be too far away for a sponanous understanding of the details of your work. I apologize for any inconvenience.
We are very grateful for your observations. We agree with some of them and could improve our work following some of your recommendations.
Round 2
Reviewer 2 Report
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