scholarly journals Double-Pulse Triple-Wire MIG Welding of 6082-T6 Aluminum Alloy: Process Characteristics and Joint Performances

Metals ◽  
2021 ◽  
Vol 11 (9) ◽  
pp. 1388
Author(s):  
Ke Yang ◽  
Fei Wang ◽  
Hongbing Liu ◽  
Peng Wang ◽  
Chuanguang Luo ◽  
...  
Keyword(s):  
Tensile Strength ◽  
Aluminum Alloy ◽  
High Efficiency ◽  
Welding Process ◽  
Pulse Frequency ◽  
Double Pulse ◽  
Fish Scale ◽  
Mig Welding ◽  
Process Characteristics ◽  
Pulse Welding

High-efficiency and high-quality welding has always been the focus of welding research. This article proposes a novel double-pulse, triple-wire MIG welding process for the welding of 6082-T6 aluminum alloy. The process characteristics of welding arc and droplet transfer were studied, and the performances of weld formation, morphology, hardness, and tensile strength were tested for the 1 Hz, 3 Hz, and 5 Hz double-pulse welding and normal-pulse welding. It was found that in the welding process, the pulsed arc steadily alternated among three welding wires without arc interruption, and the arc length changed periodically with the double-pulse frequency. The droplets transferred with a stable one-pulse-one-drop mode. Besides, a proper double-pulse frequency, e.g., 3 Hz in this case, was conducive to forming good welds with regular fish-scale patterns and no pores. The tensile strength of the joint could reach 64% of the base material’s tensile strength, and its fracture belonged to plastic fracture, which occurred in the HAZ. This new welding method will have great potential in aluminum alloy welding.

Weld Width Control System for Pulsed MIG Welding of Aluminum Alloy

2011 ◽  
Vol 299-300 ◽  
pp. 908-911
Author(s):  
Li Hui Lu ◽  
Ding Fan ◽  
Jian Kang Huang ◽  
Ming Zhu ◽  
Yu Shi
Keyword(s):  
Aluminum Alloy ◽  
Control System ◽  
Welding Process ◽  
Pulse Method ◽  
High Energy ◽  
Double Pulse ◽  
Mig Welding ◽  
Heat Accumulation ◽  
Weld Width ◽  
Vision Sensing

Due to strong heat accumulation and low surface tension of aluminum alloy, weld width will become wider, even subsidence in pulsed MIG welding process of aluminum alloy at constant parameters. A variable double-pulse method for weld width control is proposed. Weld width control is realized by changing double-pulse duty cycle that is the ratio of high-energy pulse time in a double-pulse cycle to adjust heat input based on the vision sensing for weld width. A rapid prototyping control system is built on the basis of vision sensing and xPC Target real-time environment. Then variable double-pulse MIG welding process test is done and proves the feasibility of the control scheme. On this basis, weld width control test in pulsed MIG welding of aluminum alloy is carried out and obtains a good weld with beautiful formation and uniform weld width. The results show that weld width control can be realized well with the variable double-pulse method in pulsed MIG welding of aluminum alloy.

Comparison between Plasma-MIG and MIG Procedures on 5A06 Aluminum Alloy

2008 ◽  
Vol 575-578 ◽  
pp. 1382-1388 ◽  
Author(s):  
Hong Ming Gao ◽  
Yan Bai ◽  
Lin Wu
Keyword(s):  
Tensile Strength ◽  
Aluminum Alloy ◽  
Mechanical Performance ◽  
Weld Zone ◽  
Welding Process ◽  
Deposition Efficiency ◽  
Eutectic Structure ◽  
Melting Rate ◽  
Mig Welding ◽  
5A06 Aluminum Alloy

10mm-5A06 aluminum alloy was butt-welded in a single pass by the plasma-gas metal arc (plasma-MIG) welding procedure, the joints were subjected to X-ray inspection, the microstructure and mechanical performance of weld were also studied. The results indicate that plasma-MIG welding is superior to regular conventional MIG welding on the aspects of reducing weld porosity, increasing joint quality and improving deposition efficiency. Good weld joint with less porosity and excellent mechanical properties is obtained, which can reach as 92.62% tensile strength and 85.12% elongation percentage as base metal. Dimples in which the precipitated phase is the solid solution based on Al3Mg2 are observed in fracture scanning electron micrograph and the fracture mode is ductile rupture. α-Al and Al3Mg2 ,α-Al and eutectic structure are observed respectively in fusion area and in weld zone. The wire feed rate and melting rate can come to 14.5m/min and 80g/min respectively for the 1.6mm welding wire by the plasma-MIG welding process on the premise that the tensile strength of the joints meet the requirements.

scholarly journals Stability and Heat Input Controllability of Two Different Modulations for Double-Pulse MIG Welding

2019 ◽  
Vol 9 (1) ◽  
pp. 127 ◽  
Author(s):  
Jiaxiang Xue ◽  
Min Xu ◽  
Wenjin Huang ◽  
Zhanhui Zhang ◽  
Wei Wu ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Heat Input ◽  
Double Pulse ◽  
Fish Scale ◽  
Input Energy ◽  
Mig Welding ◽  
Pulse Modulation ◽  
Welding Arc ◽  
Input Control ◽  
Welding Processes

Aluminum alloy welding frequently experiences difficulties such as heat input control, poor weld formation, and susceptibility to pore generation. We compared the use of two different modulations for double-pulse metal inert gas (MIG) welding to reduce the heat input required to generate oscillations in the weld pool. The stabilities of rectangular wave-modulated and trapezoidal wave-modulated double-pulse MIG welding (DP-MIG and TP-MIG) were analyzed by examining their welding processes and weld profiles. We found that the transitional pulse in TP-MIG welding results in smoother current transitions, softer welding arc sounds, and a highly uniform fish-scale pattern. Therefore, TP-MIG welding is more stable than DP-MIG welding. The effects of these double-pulse modulation schemes on welding input energy are presented. We propose methods for reducing welding input energy by varying the number of pulses or the pulse base time of low-energy pulse train while keeping the welding current and welding arc stable and unchanged. Compared to DP-MIG welding, TP-MIG welding reduces the input energy by 12% and produces finer grain sizes, which increases weld hardness. Therefore, TP-MIG welding offers a new approach for heat input control in DP-MIG welding of aluminum alloys. The results of this work are significant for aluminum alloy welding.

Plasma-MIG Hybrid Welding Process of 5083 Marine Aluminum Alloy

2016 ◽  
Vol 850 ◽  
pp. 519-525 ◽  
Author(s):  
De Tao Cai ◽  
Shan Guo Han ◽  
Shi Da Zheng ◽  
De Jun Yan ◽  
Jiu Qiang Luo ◽  
...  
Keyword(s):  
Tensile Strength ◽  
Aluminum Alloy ◽  
Weld Joint ◽  
Room Temperature ◽  
Welding Process ◽  
Bending Test ◽  
Hybrid Welding ◽  
Plasma Current ◽  
Mig Welding ◽  
Bending Properties

Plasma-MIG hybrid welding and MIG welding of 5083 marine aluminum alloy was carried out. The influences of parameters of welding process on the weldments morphology were investigated in order to optimize the welding process parameters. The macrostructure, microstructure, tensile and bending properties of the optimized joint were studied. The results show that Plasma-MIG hybrid welding not only has a synergistic effect of Plasma and MIG welding but also has a high welding efficiency. Welding speed, Plasma current and MIG current have a significant effect on welding penetration and welding morphology. Meanwhile, the ductility and strength property of weld joint was qualified though the bending test and tensile test. The average tensile strength of weld joint is about 285MPa at room temperature, about 86% of the base metal.

scholarly journals Comparative in Mechanical Behavior of 6061 Aluminum Alloy Welded by Pulsed GMAW with Different Filler Metals and Heat Treatments

Materials ◽  
2019 ◽  
Vol 12 (24) ◽  
pp. 4157 ◽  
Author(s):  
Isidro Guzmán ◽  
Everardo Granda ◽  
Jorge Acevedo ◽  
Antonia Martínez ◽  
Yuliana Dávila ◽  
...  
Keyword(s):  
Heat Treatment ◽  
Tensile Strength ◽  
Aluminum Alloy ◽  
Weld Joint ◽  
Welding Process ◽  
Mechanical Resistance ◽  
6061 Aluminum Alloy ◽  
Β Phase ◽  
Welding Processes ◽  
Filler Metals

Precipitation hardening aluminum alloys are used in many industries due to their excellent mechanical properties, including good weldability. During a welding process, the tensile strength of the joint is critical to appropriately exploit the original properties of the material. The welding processes are still under study, and gas metal arc welding (GMAW) in pulsed metal-transfer configuration is one of the best choices to join these alloys. In this study, the welding of 6061 aluminum alloy by pulsed GMAW was performed under two heat treatment conditions and by using two filler metals, namely: ER 4043 (AlSi5) and ER 4553 (AlMg5Cr). A solubilization heat treatment T4 was used to dissolve the precipitates of β”- phase into the aluminum matrix from the original T6 heat treatment, leading in the formation of β-phase precipitates instead, which contributes to higher mechanical resistance. As a result, the T4 heat treatment improves the quality of the weld joint and increases the tensile strength in comparison to the T6 condition. The filler metal also plays an important role, and our results indicate that the use of ER 4043 produces stronger joints than ER 4553, but only under specific processing conditions, which include a moderate heat net flux. The latter is explained because Mg, Si and Cu are reported as precursors of the production of β”- phase due to heat input from the welding process and the redistribution of both: β” and β precipitates, causes a ductile intergranular fracture near the heat affected zone of the weld joint.

Heat Transfer Simulations and Analysis of Joint Cross-Sectional Microstructure on Friction Stir Welding between Steel and Aluminium

2020 ◽  
Vol 863 ◽  
pp. 85-95
Author(s):  
Truong Minh Nhat ◽  
Truong Quoc Thanh ◽  
Tu Vinh Thong ◽  
Tran Trong Quyet ◽  
Luu Phuong Minh
Keyword(s):  
Tensile Strength ◽  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Thermal Contact ◽  
Welding Process ◽  
Welding Parameters ◽  
Thermal Imager ◽  
Sem Images ◽  
Cross Sectional ◽  
Friction Stir

This study presents conducted heat simulations and experimental jointing flat-plate of aluminum alloy 6061 and SUS 304. Temperature is simulated by the COMSOL software in three states: (1) Preheat the Friction Stir Welding (FSW) by TIG welding, (2) Thermal contact resistance between Aluminium and steel, and (3) The welding process using stiring friction is simulated. The simulations intended to predicting the temperature which is used for preheat and welding process to ensuring the required solid-state welding. The temperature is also determined and checked by a thermal imager comparing with simulation results. Besides, the results of tensile strength is carried out. The Box - Behnken method is used to identify the relationship between the welding parameters (rotation, speed and offset), temperature and tensile strength. The maximum tensile strength is 77% compared to the strength of aluminum alloy. The optimal set of parameters for the process is n = 676 rpm, v = 46 mm / min and x = 0.6 mm. The optimizing welding parameters to achieving good quality of welding process are described. SEM images to determine some properties of welding materials. This is also the basis for initial research to identify some defects in welding of two different materials (IMC thickness and interconnected pores) and the cause of these defects.

A study of tensile strength of MIG welding-brazing dissimilar lap joints of mild steel and aluminum alloy

2019 ◽  
Author(s):  
Abdulnasser Embark Beleed ◽  
A. I. M. Shaiful ◽  
Muhamad Fahmi Mohd Roslan ◽  
M. N. B. Omar ◽  
Mazlan Mohamed
Keyword(s):  
Tensile Strength ◽  
Aluminum Alloy ◽  
Mild Steel ◽  
Lap Joints ◽  
Mig Welding

Sustainable Analysis of Process Parameters during MIG Welding of 1018 Mild Steel

2022 ◽  
Vol 13 (1) ◽  
pp. 0-0
Keyword(s):  
Tensile Strength ◽  
Energy Consumption ◽  
Mild Steel ◽  
Process Parameters ◽  
Negative Impact ◽  
Sustainable Manufacturing ◽  
Welding Process ◽  
Travel Speed ◽  
Contour Plot ◽  
Mig Welding

The present work analyses MIG in terms of strength and consumption of energy during joining of similar AISI 1018 Mild Steel plates. Sustainable manufacturing is the creation of various manufactured products that generally use different processes that will minimize negative impact on environment, conserve natural resources and energy, are also safe for the employees, consumers and communities as well as economically sound. Sustainable manufacturing highlights on the necessity of an energy effective process that optimize consumption of energy. AISI 1018 mild steel is extensively used in automotive industries for pins, worms, dowels gears, non-critical tool components etc. Main important output responses are Tensile Strength and energy consumption during MIG Welding Process by taking Current, Travel Speed and Voltage as effective input variables. The main objective is to optimize energy consumption as well as tensile strength also determination of main influential process parameters on energy Consumption and tensile strength by using Taguchi Method. Contour plot has been also shown.

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