Process Parameters Optimization of an Aluminium Alloy with Pulsed Gas Tungsten Arc Welding (GTAW) Using Gas Mixtures

Pawan Kumar,Kishor Purushottamrao Kolhe,Chanchal Kumar Datta,Sashikant Janardan Morey

doi:10.4236/msa.2011.24032

Pawan Kumar, Kishor Purushottamrao Kolhe + Show 2 more

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https://doi.org/10.4236/msa.2011.24032

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Abstract

This paper demonstrates the enhancement of mechanical properties and effective optimization of pulsed GTAW process parameters on aluminium alloy 6061 using sinusoidal AC wave with argon plus helium gas mixtures. Modified Taguchi Method (MTM) was employed to formulate experimental layout and to study effect of process parameter optimization on mechanical properties of the weld joints. Microstructural characterization of weld joint was carried out to understand the structural property correlation with process parameters.

Highlights

Aluminium alloy 6061 (Al-Mg-Si alloy) is widely used in the fabrication of food processing equipment, chemical containers, passenger cars, road tankers and railway transport systems due to its high strength, excellent weldability and resistance to corrosion
This paper demonstrates the enhancement of mechanical properties and effective optimization of pulsed Gas Tungsten Arc Welding (GTAW) process parameters on aluminium alloy 6061 using sinusoidal AC wave with argon plus helium gas mixtures
Microstructures of above three samples were characterized by image analysis system for the measurement of porosity level and grain size of the weld zone and heat affected zone (HAZ)

Summary

Introduction

Aluminium alloy 6061 (Al-Mg-Si alloy) is widely used in the fabrication of food processing equipment, chemical containers, passenger cars, road tankers and railway transport systems due to its high strength, excellent weldability and resistance to corrosion. As these Al alloys (6xxx series) are precipitation-hardened, they suffer from a strength reduction in heat affected zone (HAZ) and like most face-centered cubic metals, they do not exhibit clear endurance limit [1]. Pulsed GTA welding process is frequently used for welding of aluminium alloys as heat input during welding can be precisely controlled. Pulse process variables are controlling factor for heat input, which in turn leads to grain refinement in fusion zone, width reduction of HAZ, segregation of alloying elements, reducing hot cracking sensitivity and residual stresses [3,4]

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