Optimization of TIG welding parameters and filler rod material selection for dissimilar aluminum alloy joints
Abstract The objective of this research is to enhance the mechanical characteristics of aluminum alloy welds by adjusting tungsten inert as (TIG) welding parameters. Different welding parameters, such as current (150, 170, and 190 amps), gas flow rate (10, 11, and 12 l/min), and filler rod diameter...
Saved in:
| Main Authors: | , , , , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
SpringerOpen
2025-06-01
|
| Series: | Journal of Materials Science: Materials in Engineering |
| Subjects: | |
| Online Access: | https://doi.org/10.1186/s40712-025-00296-7 |
| Tags: |
Add Tag
No Tags, Be the first to tag this record!
|
| _version_ | 1850114591029198848 |
|---|---|
| author | Kasu Karthick K. Sravanthi S. P. Jani D. Antony Prabu Senthil Vadivel T. Haiter Lenin Allasi |
| author_facet | Kasu Karthick K. Sravanthi S. P. Jani D. Antony Prabu Senthil Vadivel T. Haiter Lenin Allasi |
| author_sort | Kasu Karthick |
| collection | DOAJ |
| description | Abstract The objective of this research is to enhance the mechanical characteristics of aluminum alloy welds by adjusting tungsten inert as (TIG) welding parameters. Different welding parameters, such as current (150, 170, and 190 amps), gas flow rate (10, 11, and 12 l/min), and filler rod diameter (1.6, 2.0, and 2.4 mm), were systematically analyzed using the TOPSIS technique used in industries like aerospace, automotive, and construction, where precise welding control ensures aluminum alloy reliability and performance. It engages in multiparameter optimization which systematically ranks welding parameters, helping identify key factors that enhance weld quality. The response parameters selected were ultimate tensile strength (UTS), Vickers hardness, and percentage of elongation. A total of 31 microhardness readings were obtained to assess hardness distribution across the welded joints. Analysis of the results indicated that the filler rod diameter significantly influenced all response parameters. Specifically, it had the highest impact on UTS, elongation, and hardness, with contribution percentages of 48.4%, 52.6%, and 51.41%, respectively. The gas flow rate and welding current also affected these properties but to a lesser extent. ANOVA results showed that the filler rod diameter was the most critical factor, with high F-values and low P-values for each response parameter. The study concludes that optimizing filler rod diameter can substantially improve weld quality, making it the most influential parameter in achieving desired mechanical properties in TIG welding of aluminum alloys. |
| format | Article |
| id | doaj-art-5cdf2a7ba01f405887320e2eeef93cb2 |
| institution | OA Journals |
| issn | 3004-8958 |
| language | English |
| publishDate | 2025-06-01 |
| publisher | SpringerOpen |
| record_format | Article |
| series | Journal of Materials Science: Materials in Engineering |
| spelling | doaj-art-5cdf2a7ba01f405887320e2eeef93cb22025-08-20T02:36:50ZengSpringerOpenJournal of Materials Science: Materials in Engineering3004-89582025-06-0120111110.1186/s40712-025-00296-7Optimization of TIG welding parameters and filler rod material selection for dissimilar aluminum alloy jointsKasu Karthick0K. Sravanthi1S. P. Jani2D. Antony Prabu3Senthil Vadivel T.4Haiter Lenin Allasi5Department of Mechanical Engineering, Marri Laxman Reddy Institute of Technology and ManagementDepartment of Mechanical Engineering, Marri Laxman Reddy Institute of Technology and ManagementDepartment of Mechanical Engineering, Marri Laxman Reddy Institute of Technology and ManagementDepartment of Mechanical Engineering, Loyola-ICAM College of Engineering and Technology (LICET)School of Engineering and Technology, Manav Rachna International Institute of Research and StudiesDepartment of Mechanical Engineering, Kombolcha Institute of Technology, Wollo UniversityAbstract The objective of this research is to enhance the mechanical characteristics of aluminum alloy welds by adjusting tungsten inert as (TIG) welding parameters. Different welding parameters, such as current (150, 170, and 190 amps), gas flow rate (10, 11, and 12 l/min), and filler rod diameter (1.6, 2.0, and 2.4 mm), were systematically analyzed using the TOPSIS technique used in industries like aerospace, automotive, and construction, where precise welding control ensures aluminum alloy reliability and performance. It engages in multiparameter optimization which systematically ranks welding parameters, helping identify key factors that enhance weld quality. The response parameters selected were ultimate tensile strength (UTS), Vickers hardness, and percentage of elongation. A total of 31 microhardness readings were obtained to assess hardness distribution across the welded joints. Analysis of the results indicated that the filler rod diameter significantly influenced all response parameters. Specifically, it had the highest impact on UTS, elongation, and hardness, with contribution percentages of 48.4%, 52.6%, and 51.41%, respectively. The gas flow rate and welding current also affected these properties but to a lesser extent. ANOVA results showed that the filler rod diameter was the most critical factor, with high F-values and low P-values for each response parameter. The study concludes that optimizing filler rod diameter can substantially improve weld quality, making it the most influential parameter in achieving desired mechanical properties in TIG welding of aluminum alloys.https://doi.org/10.1186/s40712-025-00296-7TIG weldingMechanical propertiesANOVAProcess parameterAluminum alloyFiller material |
| spellingShingle | Kasu Karthick K. Sravanthi S. P. Jani D. Antony Prabu Senthil Vadivel T. Haiter Lenin Allasi Optimization of TIG welding parameters and filler rod material selection for dissimilar aluminum alloy joints Journal of Materials Science: Materials in Engineering TIG welding Mechanical properties ANOVA Process parameter Aluminum alloy Filler material |
| title | Optimization of TIG welding parameters and filler rod material selection for dissimilar aluminum alloy joints |
| title_full | Optimization of TIG welding parameters and filler rod material selection for dissimilar aluminum alloy joints |
| title_fullStr | Optimization of TIG welding parameters and filler rod material selection for dissimilar aluminum alloy joints |
| title_full_unstemmed | Optimization of TIG welding parameters and filler rod material selection for dissimilar aluminum alloy joints |
| title_short | Optimization of TIG welding parameters and filler rod material selection for dissimilar aluminum alloy joints |
| title_sort | optimization of tig welding parameters and filler rod material selection for dissimilar aluminum alloy joints |
| topic | TIG welding Mechanical properties ANOVA Process parameter Aluminum alloy Filler material |
| url | https://doi.org/10.1186/s40712-025-00296-7 |
| work_keys_str_mv | AT kasukarthick optimizationoftigweldingparametersandfillerrodmaterialselectionfordissimilaraluminumalloyjoints AT ksravanthi optimizationoftigweldingparametersandfillerrodmaterialselectionfordissimilaraluminumalloyjoints AT spjani optimizationoftigweldingparametersandfillerrodmaterialselectionfordissimilaraluminumalloyjoints AT dantonyprabu optimizationoftigweldingparametersandfillerrodmaterialselectionfordissimilaraluminumalloyjoints AT senthilvadivelt optimizationoftigweldingparametersandfillerrodmaterialselectionfordissimilaraluminumalloyjoints AT haiterleninallasi optimizationoftigweldingparametersandfillerrodmaterialselectionfordissimilaraluminumalloyjoints |