Abstract

Tungsten Inert Gas (TIG) welding is highly regarded as the primary welding method, especially for challenging metals like aluminum. Pulsed current TIG welding has been specifically developed for welding aluminum alloys. Composite weld joints of aluminum alloys AA5052 and AA6063 find extensive use in diverse sectors, such as automotive and marine applications, where significant mechanical properties and corrosion resistance are required. It is crucial to carefully select the process parameters to achieve the desired mechanical and physical properties in the welded structure. The ASME Section IX provides valuable guidelines for determining the essential input parameters for TIG welding. This research project aims to investigate the influence of specific welding parameters, including Peak current, Base current, and Pulse per second. For the composite welding of 8mm thick plate joints of AA5052 alloy and AA6063 alloy, ER4043 filler wire is employed. Tensile tests are carried out to evaluate the composite joints’ mechanical characteristics and weld strength. The central composite design (CCD) and regression analysis are applied to identify the welding parameter that significantly affects the results. The response surface optimizer is utilized to optimize the selected parameters, and the final outcome is thoroughly evaluated, which meets the requirements as per ASME/ASTM standards.

Keywords: Aluminum composite alloys, AA5052 alloy, AA6063 alloy, pulsed current TIG welding, tensile strength, hardness, response surface method

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Abstract

Tungsten Inert Gas (TIG) welding is highly regarded as the primary welding method, especially for challenging metals like aluminum. Pulsed current TIG welding has been specifically developed for welding aluminum alloys. Composite weld joints of aluminum alloys AA5052 and AA6063 find extensive use in diverse sectors, such as automotive and marine applications, where significant mechanical properties and corrosion resistance are required. It is crucial to carefully select the process parameters to achieve the desired mechanical and physical properties in the welded structure. The ASME Section IX provides valuable guidelines for determining the essential input parameters for TIG welding. This research project aims to investigate the influence of specific welding parameters, including Peak current, Base current, and Pulse per second. For the composite welding of 8mm thick plate joints of AA5052 alloy and AA6063 alloy, ER4043 filler wire is employed. Tensile tests are carried out to evaluate the composite joints’ mechanical characteristics and weld strength. The central composite design (CCD) and regression analysis are applied to identify the welding parameter that significantly affects the results. The response surface optimizer is utilized to optimize the selected parameters, and the final outcome is thoroughly evaluated, which meets the requirements as per ASME/ASTM standards.

Keywords: Aluminum composite alloys, AA5052 alloy, AA6063 alloy, pulsed current TIG welding, tensile strength, hardness, response surface method

🔒 This is a subscription article

Full text is available to subscribers and institutional members. Please choose an option below to access it.