Various journal papers show that many researchers study the effect of process parameters by using bead on weld type and not butt joint weld.e.g. almost all papers on activated tig welding show that welding is done on bead on weld type. What is the reason behind this?
easy to prepare, almost zero distortion, good geometry, get rid of clamping, but less penetration as compare to butt joint
Michael Rethmeier, Nitin Saini Could you please explain why the depth of penetration is lower in bead on plate compared to butt joint, for the same amount of heat input?
I agree with Prof. Rethmeier. Our X-ray observation results show that the liquid metal may drop down through the gap in the butt welding, which will increase the penetration. Our following papers show the keyhole and molten pool in butt welding situation and bead-on-plate welding situation, respectively.
Article In-situ observation of gap filling in laser butt welding
Article Effect of alloy element on weld pool dynamics in laser weldi...
It all depends on your goal. Usually, bead on plate is the first stage. You test the bead appiarance, stability or other properties of interest to you, and in the case of a positive result, go to special samples.You save money and time.
Another reason for this is that you can easily obtain a same or very similar welding conditions for comparison of results (e. g., with or without activated flux) if you use bead on plate welding, while if butt welding is conducted, you should pay attention to the gap, groove, mismatch......The welding condition will be different if any of them changes and experiment results for comparison will lose their significance.
Bead on plate welding is relatively easy than the butt welding as it eliminates the chances of gap, mismatch etc, which may lead to some welding defects or strength reduction. Moreover, it is some times conducted as a preliminary step to set parameters suitable to obtain full penetration butt welding.
I am agree with Dewasish in a totality. It is easy to make weld on plate weld and risk for mismatch is less. For comparison of results are also judging well for the plate weld. In plate weld advantage is gap is negligible in comparison to butt weld. Good geometry and less distortion are also reason behind chosen over the butt weld.Molten pool in butt weld is another reason for the preference over the butt weld. All these reason aforementioned above are preferred.
While experimentation with bead on plate trials we have full base material, for butt joints we have to consider gaps, groove angle, arc length correction etc, ie. less base material for welding. In addition, in many cases there will be oxides on the edges that will also influence the penetration of the weld.
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