Tungsten inert gas welding of two aluminum alloys using filler rods containing scandium: the role of process parameters

The present work investigates the effects of selected welding process parameters on the output responses for the tungsten inert gas welding of two aluminum alloys: 5083-H111 and 5754-H111. The tungsten inert gas welding was performed using design of experiments followed by the optimization of process parameter through response surface methodology technique. Tungsten inert gas welding was carried out by varying current, gas flow rate, and weight percentage of scandium addition on the filler rod and tensile strength and microhardness were measured as output responses. From the analysis of variance results, it was found that the significant influencing parameter to be input current for the tungsten inert gas welding. For predicting optimal ultimate tensile strength and microhardness, desirability approach was used. The optimized process parameters were found to be input current of 170 A, gas flow rate of 11 lit/min, and weight percentage of scandium added filler rod of 0.5%. The peak tensile strength and microhardness values observed for the optimum process parameters were 236.18 MPa and 105 HV, respectively. The validation of the optimization found these values from the experiments consistent with the predicted values with marginal error. The microstructure of the base alloys and the weld zone were analyzed.

Automated summary

This study optimized the process parameters of tungsten inert gas welding through experiments and response surface methodology, enhancing the strength and hardness of aluminum alloy welding.