Effect of weld geometry on fatigue performance of 6061-T6 aluminum GMAW: part 3. T-fillet joint

The effects of various weld geometries on the fatigue performance of T-fillet joint aluminum arc welding were investigated by conducting gas metal arc weld (GMAW) experiments using 6061-T6 material for various weld geometries. The results of the fatigue tests conducted using a 5-ton grade tester demonstrated that the fatigue performance of T-fillet joint aluminum arc welding is primarily affected by the area of the welded part and weld reinforcement. A large welded area can be obtained by full penetration, and a large weld reinforcement can be obtained by a large throat size and a small toe angle. Contrary to expectations, it was observed that optimal size and higher quantity of porosities can increase fatigue performance. This can be attributed to porosities behaving similarly to crack stop holes, which can prevent stress focusing. The deviation in fatigue performance in the case of minute penetration depth and minute throat size is not remarkable. Therefore, deeper penetration and larger weld reinforcement are crucial factors in obtaining higher fatigue performance in the industry.

Automated summary

This study investigated the effects of different weld geometries on the fatigue performance of T-fillet joint aluminum arc welding. The results showed that the area of the welded part and weld reinforcement were the primary factors affecting fatigue performance, with full penetration and larger weld reinforcement leading to improved fatigue performance. Surprisingly, optimal size and higher quantity of porosities were found to increase fatigue performance.