Paper Title
Design and Analysis of Lap Joint Welding Fixture

Abstract
Welding is recognized as a fundamental joining process that is extensively employed to connect both metallic and non-metallic materials through localized melting beyond their melting point. Nevertheless, the heat generated during the welding process frequently results in geometric imperfections such as distortion and misalignment, thereby compromising structural integrity and dimensional accuracy. To mitigate these issues, a welding fixture was designed and developed to securely hold and accurately position the workpiece before, during, and after the welding operation. This study was conducted to design and evaluate a fixture specifically intended for lap joint welding using the Gas Metal Arc Welding (GMAW) process. The fixture was designed using Autodesk Inventor Professional, and aluminium alloy Al 6061 was selected as the base material due to its superior machinability and thermal conductivity. The effectiveness of the developed fixture was assessed through experimental trials involving ten respondents, each performing welding tasks both with and without the fixture. The experimental results indicated a significant enhancement in operational efficiency. Welding operations conducted with the fixture demonstrated a 37% reduction in average welding time compared to those performed without the fixture. Furthermore, the findings from a user perception survey revealed positive evaluations, with mean scores of 4.34 for the perception of fixture usability and 4.25 for confidence in welding using the fixture. These results substantiate that the implementation of the developed fixture contributes to improved productivity, enhanced weld quality, greater user confidence, and reduced setup time in GMAW lap joint welding applications. Keywords - Welding Fixture; Gas Metal Arc Welding (GMAW); Lap Joint; Aluminum 6061; Distortion Reduction