Skip to main content
SpringerLink
Log in

Effect of GTAW process parameters on weld characteristics and microstructural studies of dissimilar welded joints of AA5083 and AA6082: optimization technique

  • Original Paper
  • Published:
International Journal on Interactive Design and Manufacturing (IJIDeM) Aims and scope Submit manuscript

Abstract

In this research, dissimilar plates of AA5083 and AA6082 were used to develop the dissimilar components where high corrosion resistance and good mechanical properties required especially in aerospace industries. TIG welding set-up has been made to join these dissimilar joint using ER4043 as filler rod. The parameters such as current, time and filler rod diameter were selected at three levels. The design of experimentation was made according to L-9 orthogonal array. After welding, samples were sliced into various specimens to conduct mechanical testing’s. Tensile test was conducted on UTM as per ASTM E/8 standard. Izod test was conducted to calculate the impact energy observed before fracture under Charpy testing machine. Brinell hardness values were evaluated by testing the weld surface hardness. The output response factors like UTS, impact strength and hardness were considered as response factor to study the effect of parameters. ANOVA has been performed on output response and the analysis results were presented. From the ANOVA, the welding speed (52.54%) exerted a major effect on responses followed by weld current (22.83%) and filler diameter (20.18%). The grain boundaries with fine structures were identified at AA6082 interface whereas coarse grain structures were observed at 5083 interface due to the thermal properties.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6

Similar content being viewed by others

References

  1. Arun, D., DevendranathRamkumar, K., Vimala, R.: Multi-pass arc welding techniques of 12 mm thick super-duplex stainless steel. J. Mater. Process. Technol. 271, 126–143 (2019). https://doi.org/10.1016/j.jmatprotec.2019.03.031

    Article  Google Scholar 

  2. Wang, H., Hu, S., Shen, J., Li, D., Lu, J.: Effect of duty cycle on microstructure and mechanical properties of pulsed GTAW lap joint of Invar. J. Mater. Process. Technol. 243, 481–488 (2017). https://doi.org/10.1016/j.jmatprotec.2017.01.008

    Article  Google Scholar 

  3. Yelamasetti, B., et al.: Surface modification of aluminum alloy 6061 by embedding B4C particles via friction stir processing. Mater. Res. Express 9, 056511 (2022). https://doi.org/10.1088/2053-1591/ac6da7

    Article  Google Scholar 

  4. Balram, Y., VishuVardhan, T., Sridhar Babu, B., VenkatRamana, G., Preethi, C.: Thermal stress analysis of AISI 316 stainless steels weldments in TIG and pulse TIG welding processes. Mater. Today Proc. 19, 182–187 (2019). https://doi.org/10.1016/j.matpr.2019.06.695

    Article  Google Scholar 

  5. BalramYelamasetti, G., Ramana, V., et al.: Numerical and experimental residual stress analysis of dissimilar metals of Inconel 718 and AISI 316 developed in GTAW process. Int. J. Interact. Des. Manuf. (2022). https://doi.org/10.1007/s12008-022-00932-y

    Article  Google Scholar 

  6. Yelamasetti, B., VenkatRamana, G., Manikyam, S., Saxena, K.K.: Multi-response Taguchi grey relational analysis of mechanical properties and weld bead dimensions of dissimilar joint of AA6082 and AA7075. Adv. Mater. Process. Technol. 8, 1474–1484 (2021). https://doi.org/10.1080/2374068X.2021.1946340

    Article  Google Scholar 

  7. Yelamasetti, B., Kumar, P.N., VenkatRamana, G., Saxena, K.K., Msomi, V., Vishwanatha, H.M., et al.: Surface modification of aluminum alloy 6061 by embedding B4C particles via friction stir processing. Mater Res Express. 9(5), 056511 (2022)

    Article  Google Scholar 

  8. Wu, L., Yang, B., Han, X., Ma, G., Xu, B., Liu, Y., et al.: The microstructure and mechanical properties of 5083, 6005A and 7N01 aluminum alloy gas metal arc-welded joints for high-speed train: a comparative study. Metals (Basel) 12(213), 1–15 (2022)

    Google Scholar 

  9. Kumar, R., Kumar, G., Roy, A., Sinha, R.S., Hasnain, S.M.M., Prakash, O., et al.: A comparative analysis of friction stir and tungsten inert gas dissimilar AA5082-AA7075 butt welds. Mater. Sci. Energy Technol. 5, 74–80 (2022)

    Google Scholar 

  10. Qin, Q., Zhao, H., Li, J., Zhang, Y., Zhang, B., Su, X.: Microstructures and mechanical properties of TIG welded Al–Mg2Si alloy joints. J. Manuf. Process. 56, 941–949 (2020). https://doi.org/10.1016/j.jmapro.2020.05.058

    Article  Google Scholar 

  11. Mehdi, H., Mishra, R.S.: Effect of friction stir processing on mechanical properties and wear resistance of tungsten inert gas welded joint of dissimilar aluminum alloys. J. Mater. Eng. Perform. 30, 1926–1937 (2021). https://doi.org/10.1007/s11665-021-05549-y

    Article  Google Scholar 

  12. Mehdi, H., Mishra, R.S.: An experimental analysis and optimization of process parameters of AA6061 and AA7075 welded joint by TIG+FSP welding using RSM. Adv. Mater. Process. Technol. 8(1), 598–620 (2022). https://doi.org/10.1080/2374068X.2020.1829952

    Article  Google Scholar 

  13. Mabuwa, S., Msomi, V., Mehdi, H., Saxena, K.K.: Effect of material positioning on Si-rich TIG welded joints of AA6082 and AA8011 by friction stir processing. J. Adhes. Sci. Technol. (2022). https://doi.org/10.1080/01694243.2022.2142366

    Article  Google Scholar 

  14. Hashmi, A.W., Mehdi, H., Mabuwa, S., et al.: Influence of FSP parameters on wear and microstructural characterization of dissimilar TIG welded joints with Si-rich filler metal. Silicon 14, 11131–11145 (2022). https://doi.org/10.1007/s12633-022-01848-8

    Article  Google Scholar 

  15. Salah, A.N., Mabuwa, S., Mehdi, H., et al.: Effect of multipass FSP on Si-rich TIG welded joint of dissimilar aluminum alloys AA8011-H14 and AA5083-H321: EBSD and microstructural evolutions. Silicon 14, 9925–9941 (2022). https://doi.org/10.1007/s12633-022-01717-4

    Article  Google Scholar 

  16. Chuaiphan, W., Srijaroenpramong, L.: Optimization of TIG welding parameter in dissimilar joints of low nickel stainless steel AISI 205 and AISI 216. J. Manuf. Process. 58, 163–178 (2020). https://doi.org/10.1016/j.jmapro.2020.07.052

    Article  Google Scholar 

  17. Koli, Y., Yuvaraj, N., Aravindan, S.: Multi-response mathematical model for optimization of process parameters in CMT welding of dissimilar thickness AA6061-T6 and AA6082-T6 alloys using RSM-GRA coupled with PCA. Adv. Ind. Manuf. Eng. 2, 100050 (2021). https://doi.org/10.1016/j.aime.2021.100050

    Article  Google Scholar 

  18. Sonar, T., Balasubramanian, V., Malarvizhi, S., Venkateswaran, T., Sivakumar, D.: Multi-response mathematical modelling, optimization and prediction of weld bead geometry in gas tungsten constricted arc welding (GTCAW) of Inconel 718 alloy sheets for aero-engine components. Multiscale Multidis. Model Exp. Des. 3(3), 201–226 (2020). https://doi.org/10.1007/s41939-020-00073-3

    Article  Google Scholar 

  19. Goyal, A., Kapoor, H., Jayahari, L., Saxena, K.K., UmmalSalmaan, N., Mohammed, K.A.: Experimental investigation to analyze the mechanical and microstructure properties of 310 SS performed by TIG welding. Adv. Mater. Eng. 2022, 1–11 (2022). https://doi.org/10.1155/2022/1231843

    Article  Google Scholar 

  20. Avinash, S., YelamasettiBalram, B., Sridhar Babu, B., Venkatramana, G.: Multi-response optimization of pulse TIG welding process parameters of welds AISI 304 and Monel 400 using grey relational analysis. Mater. Today Proc. 19, 296–301 (2019). https://doi.org/10.1016/j.matpr.2019.07.211

    Article  Google Scholar 

  21. Badiger, R.I., Narendranath, S., Srinath, M.S.: Optimization of parameters influencing tensile strength of inconel-625 welded joints developed through microwave hybrid heating. Mater. Today Proc. 5(2), 7659–7667 (2018)

    Article  Google Scholar 

  22. Yelamasetti, B., Rajyalakshmi, G., Sravan, K.K.: Mechanical and microstructural studies of optimized taguchi grey relational analysis of pcgtaw process parameters for joining monel 400 and aisi 316. UPB Sci. Bull. Ser. B Chem. Mater. Sci. 83(3), 253–264 (2021)

    Google Scholar 

  23. Pasupathy, J., Ravisankar, V.: Influences of TIG Welding Parameters on Tensile Behavior of Dissimilar Metal Lap Joint for Low Carbon Steel and AA1050, pp. 493–498. Woodhead Publishing Limited, Sawston (2013)

    Google Scholar 

  24. Nourani, M., Milani, A.S., Yannacopoulos, S.: Taguchi optimization of process parameters in friction stir welding of 6061 aluminum alloy: a review and case study. Engineering 03(02), 144–155 (2011)

    Article  Google Scholar 

  25. Balaram Naik, A., Chennakeshava, R.A.: Optimization of tensile strength in TIG welding using the Taguchi method and analysis of variance (ANOVA). Therm. Sci. Eng. Prog. 8, 327–339 (2018). https://doi.org/10.1016/j.tsep.2018.08.005

    Article  Google Scholar 

  26. Nait Salah, A., Mehdi, H., Mehmood, A., Hashmi, A.W., Malla, C., Kumar, R.: Optimization of process parameters of friction stir welded joints of dissimilar aluminum alloys AA3003 and AA6061 by RSM. Mater. Today Proc. 56, 1675–1683 (2022). https://doi.org/10.1016/j.matpr.2021.10.288

    Article  Google Scholar 

  27. Mehdi, H., Mehmood, A., Chinchkar, A., Hashmi, A.W., Malla, C., Mohapatra, P.: Optimization of process parameters on the mechanical properties of AA6061/Al2O3 nanocomposites fabricated by multi-pass friction stir processing. Mater. Today Proc. 56(4), 1995–2003 (2022). https://doi.org/10.1016/j.matpr.2021.11.333

    Article  Google Scholar 

  28. Mehdi, H., Mishra, R.S.: Influence of friction stir processing on weld temperature distribution and mechanical properties of TIG-welded joint of AA6061 and AA7075. Trans. Indian Inst. Met. 73(7), 1773–1788 (2020). https://doi.org/10.1007/s12666-020-01994-w

    Article  Google Scholar 

  29. Mehdi, H., Mishra, R.S.: Modification of microstructure and mechanical properties of AA6082/ZrB2 processed by multipass friction stir processing. J. Mater. Eng. Perform. 32, 285–295 (2023). https://doi.org/10.1007/s11665-022-07080-0

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, GLA University, Mathura, UP, 281406, India

    Ajit Kumar Yadav & Manoj Kr. Agrawal

  2. Division of Research and Development, Lovely Professional University, Phagwara, Jalandhar, India

    Kuldeep K. Saxena

  3. Department of Mechanical Engineering, MLR Institute of Technology, Hyderabad, Telangana, 500043, India

    Balram Yelamasetti

Authors
  1. Ajit Kumar Yadav
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Manoj Kr. Agrawal
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Kuldeep K. Saxena
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Balram Yelamasetti
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Balram Yelamasetti.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Yadav, A.K., Agrawal, M.K., Saxena, K.K. et al. Effect of GTAW process parameters on weld characteristics and microstructural studies of dissimilar welded joints of AA5083 and AA6082: optimization technique. Int J Interact Des Manuf 18, 1151–1160 (2024). https://doi.org/10.1007/s12008-023-01230-x

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s12008-023-01230-x

Keywords

Search

Navigation