Modeling and Optimization of Solidification Cracking of 4043 Aluminum Alloys Produced by Cold Metal Transfer Welding

Studying the effects of key processing parameters during the actual production of aluminum alloys produced by cold metal transfer (CMT) welding on solidification cracks is pivotal to reducing their occurrence and greatly improving the quality of the products. In this work, a mathematical model based on the response surface methodology (RSM) is developed to analyze the influence of the multi-factor processing parameters of 4043 aluminum alloys produced by CMT welding on their susceptibility to solidification cracks and the optimization of the crack rate. The results show that the mathematical model is reliable and predictable. However, due to the complexity of the polynomial model, it is difficult for it to predict which parameters are prone to crack formation. After calculating the RSM, it is found that wire feeding speed and wire withdrawal are more likely to cause solidification cracks. Furthermore, the processing parameters are optimized by minimizing the susceptibility to solidification cracks. Consequently, a visual parameter map with crack-free curve boundaries is obtained and the crack-free area is calculated to facilitate operation.

Automated summary

A mathematical model based on the response surface methodology (RSM) is developed to analyze the effects of key processing parameters on solidification cracks in aluminum alloys produced by cold metal transfer (CMT) welding. The model is shown to be reliable and capable of predicting the occurrence of cracks. Wire feeding speed and wire withdrawal are identified as the critical factors leading to solidification cracks. The optimization of processing parameters results in a visual parameter map that indicates the crack-free area for easier operation.