Gas-Tungsten Arc Welding of Dissimilar Aluminum Alloys With Nano-Treated Filler

Arc welding of dissimilar aluminum alloys is in high demand in industry but often challenging in practice. Dissonant material properties between the base metals often lead to solidification cracking in the weld metal upon cooling. Here, we report a nano-treatment approach that infuses TiC nanoparticles into filler material mimicking commercial ER5183 to successfully join dissimilar systems of AA2024 + AA5083 and AA2024 + AA7075 with the gas-tungsten arc welding process. Welded specimens were free of hot cracking, and microstructural studies revealed globular, refined grains smaller than 20 mu m in the weld metals of both systems. Mechanical properties of both systems were examined with microhardness and tensile testing, and they showed sound behavior in their as-welded conditions. Nano-treatment therefore presents a new way to reliably weld dissimilar systems that are traditionally considered unweldable.

Automated summary

Arc welding of dissimilar aluminum alloys is challenging due to solidification cracking caused by dissonant material properties. A nano-treatment approach using TiC nanoparticles in filler material successfully joined different systems with gas-tungsten arc welding, producing weld metals with refined grains and sound mechanical properties. This method provides a new way to reliably weld traditionally considered unweldable dissimilar systems.