SCHOOL OF ENGINEERING AND

TECHNOLOGY
Failure Mode and Effect Analysis on Welding
Assembly Process
PBL Project
By:

1) Binita Thapa Magar

2) Sapan Sunwar
3) Shishir Acharya
4) Sushan Nepal

Plot No.32-34, Knowledge Park III, Greater

Noida, U.P.
Pin code - 201306
INDIA
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 Failure Mode and Effect Analysis on
Welding Assembly process
Introduction:
In this ever-growing world of advancement and technology, there has been a huge demand for
parts and materials to make advanced products and technologies, hence resulting in having
countless number of productions and manufacturers in the world. This has led to a tough
competition among the manufacturers or factories. In a single day, factories have to produce
large numbers of parts and materials and are done with very minimal breaks or no breaks at all.
Factories are very busy and of course naturally there must be some failures in a very stressful
and monotonous environment.
In general, failure means the inability of any product or material to function or work properly as
per its intended requirements. There are many failures in mechanical engineering such as in
gears, motors, pulley, etc. The failure causes great impact in the functioning of the material
which can also be a threat or a danger to the users. To overcome this failure and its effects we
have to deeply study and analyze about its root causes and try to find solution for it. The failure
may be caused due to wrong use of tools while making the material or not making the material as
per the requirements of the design and so on[1].

Similar failure can be observed on welding assembly process. There are many causes for it,
which may be due to insufficient voltage supply during welding, inadequate type of material
used for welding and etc. Many harmful effects can be seen due to failure of welding which may
cause effects in the proper application of the material.
In general, failure mode means the way by which a material can fail that tends it not to function
properly. Failures are any potential or actual errors or defects especially the ones that can affect
the customers. Effect analysis means to study or analyze of what the consequences of those
failures are.
Failure Mode and Effect Analysis (FMEA) is a great technique where we can find why the
material actually fails and possible effects caused by failure can be analyzed and easily overcome
the possible failures and its effects. FMEA is one of the most successful tools to find the failure
mode and its effects in the manufacturing process. It is a step by step approach to identify all
possible failures in a design, manufacturing or assembly process, or a product or service. FMEA
is a common process analysis tool and also one of the first highly structured and systematic
techniques for failure analysis. FMEA helps to take action by understanding risks of failure by
documenting the current knowledge. Failure Mode and Effects Analysis (FMEA) is a systemized
group of activities by the help of which one can recognize and evaluate the potential failure and

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effects caused due to it, eliminate the failure that occurs by identifying the action that causes
failure and document analysis findings[2].

Basically, FMEA enhances good engineering by helping us to apply knowledge and experience
of Gross Functional Team to review the design process that helps to prevent the risk of failure.
FMEA helps to take action for reducing or completely eliminating failures which is started from
high priority order. FMEA is used during design to prevent failures.
The explanation behind FMEA is to dismember the arrangement characteristics relative with the
orchestrated Manufacturing cycle to guarantee that the resultant item addresses client issues and
desires. Exactly when strategies for frustration are recognized, improvement should be
conceivable by decreasing the chances for occasion by taking a couple of right activities. FMEA
gives a figured out examination of dissatisfaction strategies for the system being described and
recognizes related causes Restorative action thoughts. Used in both the arrangement and
collecting measures, they liberally decrease costs by perceiving thing and cycle improvements in
front of timetable in the make cycle right when changes are commonly basic and unobtrusive to
make. The result procured found solid, as the prerequisite for post healing movement and issues
are diminished completely. This endeavor plates and execution of Cycle Failure mode and effect
assessment for improvement in all sub-measures needed till the fulfillment of welding measure.
It is philosophy for breaking down potential dependability issues from the get-go in the
improvement cycle where it is simpler to take activities to defeat these issues, in this way
upgrading unwavering quality through plan. FMEA is absolutely a systematic approach used to
guarantee that potential issues have been thought of and tended to all through the item and cycle
improvement cycle. A cycle or a plan ought to be broke down first before it is executed and
furthermore before working a machine the disappointment modes and impact must be examined
fundamentally[3].

In this work, measure disappointment mode and impact examination is done on broad TIG
welding measure. A progression of welding with various example pieces are done and the likely
disappointments and deformities of the work piece are ordered dependent on FMEA, hazard need
numbers are appointed to everyone and by duplicating the evaluations of event, seriousness and
identification. At last the most unsafe disappointment as indicated by the RPM numbers is found
and the reason and impacts alongside the preventive measures are organized. This work fills in as
disappointment anticipation direct for the individuals who play out the welding activity towards
a successful weld[4].

By applying PFMEA we can find how fundamental the cycle is and we can make a transition to
diminish the mistake in thing and improve the gathering cycle. This paper is acquainted with
give the short knowledge in regards to the execution of the Product Failure Modes and Effects
Analysis (PFMEA) in welding cycle to improve the idea of the thing. As the little and medium
organizations are facing issues with their cycle disillusionments. So an assessment is finished in

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this regard to control these mistake in the organizations with the objective that proper quality can
be kept up at every level of work. In this assessment gives up delivered by welding measure is
thought of and sensible game plans are used to take out these disfigurements and
dissatisfactions[5].

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 Literature Table:
Research
Authors Title Findings
Parameters
 FMEA objectives, procedures
Sawadadkar, G S Failure Mode and Effect  Electrode consumption and advantages.
Analysis (FMEA) on  Porosity  FMEA is the key reliability
Dhage, H K Welding Assembly  Tungsten or oxide analysis tool to help detect
Process early failures and future
Thorat, R R
potential failures for effective
Rankhambe, D B[6] maintenance management.

Company, Ford Motor Chapter 4 Failure Mode  Tensile Strength  None of the valves in a trial
and Effects Analysis  Weld Crack batch of 57,000 valves of
Company, Ford Motor[7] ( Fmea ) – Case Study  Run out passenger car exhaust valve
line was rejected due to micro
crack in ultrasound testing.
 The tensile strength was well
over the limit of 700N/mm2.
 Spindle runout is below 100
micron.

Chikhale, Shekhar S Failure Mode and Effect  Voltage  Systematic analysis of FMEA
Analysis on Base  Gun Travelling Speed has provided large
Barik, Manoj Kumar[8] Frame – Case Study  Cutting Environment improvement in efficiency.
 Type of filler metal  Implemented in LEMKEN
INDIA AGRO EQUIPMENT
PVT. LTD. Bhuttibori, Nagpur
on welding process to reduce
the failure in the base frame.
 Maximum improvement is
done in the Gun travelling
speed.

Doshi, Jigar Application of failure  Dimensions of product  Noticeably demonstrates that

mode & effect analysis  Forging pressure continuous quality
Desai, Darshak[9] (FMEA) for continuous  Filling of material improvement can be achieved
quality improvement by effective implementation of

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 FMEA in automative SMEs.
 Identified improvement points
and their effects were different
for individual case companies
but all of them showed
continuousquality
improvement.
 Improvement was seen both
qualitatively and quantitatively.

Tripathi, Shashank[10] Study of the Product  Current  To improve the efficiency and
Failure Modes and  Under cuts effectiveness of manufacturing
Effects Analysis  Blow hole process failure are applied by
( PFMEA ) on Welding  Lack of Penetration using FMEA.
Process- A  On basis of parameters
Implementation Paper proposed for avoiding possible
risks and ultimately decrease
the loss to the industries in
terms of money, time and
quality.

Paper, Conference IMPLEMENTATION  Welding Speed  Proposed improvements

FAILURE MODE AND  Welding Process recommended to company of
Fitriana, Rina EFFECT ANALYSIS  Undercut the most potential failure.
( FMEA ) METHOD  Slag Inclusion  Test calculations are ANOVA
Trisakti, Universitas AND KNOWLEDGE and Tukey test.
MAP ( CASE ...
Fitriana, Rina[11]

Rajenthirakumar, D Defect Reduction in  Welding Current  Lacking of fusion, lacking of

Gas Tungsten Arc  Joint Configuration penetration and porosity are
Karthik, T Welding Process Using  Torch Angle the major defects according to
Failure Mode Effects  Weld arc the Pareto Chart and that
Janarthanan, V Analysis process parameters are
essential to eliminate the
Nanthakumar, S
defects.
Nadu, Tamil[12]  The major rate of defect is
caused by low skilled workers
and lack of proper standards in
production with root gap and
edge preparation impacting the

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 rate of defect.

Donders, Stijn The Effect of Spot Weld  Strength  6% of all spot welding
Failure on Dynamic  Stiffness connections were broken
Brughmans, Marc Vehicle Performance  Vibration initially with uniform selection
 Fatigue then with weighted-uniform
Hermans, Luc selection procedure.
 After comparing statistical
International, L M S
properties of scatter clouds it
Tzannetakis, Nick has been concluded that the
dynamic vehicle characteristics
Solutions, Noesis are affected by spot weld
failure.
Carlo, Monte[13]

Kalraiya, Prakhil ISSN : 2455-6203  Voltage  The introduction of FMEA in

International Journal of  Current welding processes led to
Kalraiya, Sanjay[14] Science Management &  Porosity various defects not being seen
Engineering Research (  Lack of penetration in the samples and with the
IJSMER ) A Study on continuous of FMEA, the
Reduction of Defects in production and products can
Welding Process Using be of better quality.
Product Failure Mode
and Effects Analysis
( PFMEA )

Luo, Jiehan Microstructure and  Shrinkage  Found on FZ with hardness of

failure analysis of  Stress 562.21 HV.
Zhou, Zhaoyao resistance projection  Welding voltage  Resistance projection welding
welding of nuts to AHSs  Microstructure and joints consists of interfacial
Cao, Xiaobing with capacitor discharge failure mode, pullout failure
harness profile
welding mode and projection failure
Zou, Chunhua
mode.
Zou, Chunya[15]  When welding voltage exceeds
450V, weld joint tends to fail in
mix mode of pullout failure and
interfacial failure or pullout
failure and projection failure.
Shear crack can be seen on
each joint but joint fails in IF
mode or projection failure
mode.

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 EPRI[16] Failure modes and  Surface temperature  Chloride-induced stress
effects analysis (FMEA)  Applied stress corrosion cracking (CISCC)
of welded stainless  Composition of surface turned out to be the biggest
steel canisters for dry deposits concern causing penetration
cask storage systems of confinement boundary.

Dakshinamoorthy, Arun[17] A CRITICALITY STUDY  Ventilation  Welding machine is analyzed

BY DESIGN FAILURE  Input currents and notes down the expected
MODE AND EFFECT  Surrounding environment failures.
ANALYSIS ( FMEA )  Cable location from  Proper actions should be taken
PROCEDURE IN welding area before welding and proper
LINCOLN V350 PRO maintenance should be done
WELDING MACHINE for effective welding.
 Preventive measures of
possible failures with their
priorities are given.

Tovaglieri, Alessio[18] Critical consideration  Pressure  Add inputs at any time and use
and improvement of the  Shrinkage cavity the complete FMEA
FMEA  Condition of shaft documentation.
 Must be involved in the FMEA
throughout the process of
development.
 Increment of FMEA is
proposed.
 Results should influence the
whole evaluation complex.

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 References:
[1] M. Del Mundo, “Fmea handout.” https://www.slideshare.net/MonchitoDelMundo/fmea-
handout (accessed Oct. 20, 2020).
[2] ASQ, “What is FMEA? Failure Mode & Effects Analysis,” 2012.
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Effect Analysis on Welding Assembly Process,” pp. 41–45, 2019.
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[13] S. Donders et al., “The Effect of Spot Weld Failure on Dynamic Vehicle Performance,”
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