Optimization of welding strength in the tungsten inert gas welding process for aluminium alloys
Aluminium alloys, particularly AA 6065 T6, are widely used in automotive components such as coolers and radiators due to their excellent strength-to-weight ratio and corrosion resistance. However, welding these alloys presents significant challenges, as the weld joints are prone to thermal stresses,...
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Frontiers Media S.A.
2025-05-01
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| Series: | Frontiers in Mechanical Engineering |
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| Online Access: | https://www.frontiersin.org/articles/10.3389/fmech.2025.1569059/full |
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| author | Amit Gupta Rajeev Ranjan Robert Cep Ajay Kumar Ajay Kumar Sanjay Kumar Jha Faisal Altarazi Ashish Kumar Namrata Dogra |
| author_facet | Amit Gupta Rajeev Ranjan Robert Cep Ajay Kumar Ajay Kumar Sanjay Kumar Jha Faisal Altarazi Ashish Kumar Namrata Dogra |
| author_sort | Amit Gupta |
| collection | DOAJ |
| description | Aluminium alloys, particularly AA 6065 T6, are widely used in automotive components such as coolers and radiators due to their excellent strength-to-weight ratio and corrosion resistance. However, welding these alloys presents significant challenges, as the weld joints are prone to thermal stresses, leading to defects and eventual failure. To address this issue, optimizing the PCTIG (Pulsed Current Tungsten Inert Gas) welding process parameters is crucial for achieving superior mechanical properties, particularly tensile strength. This study investigates the influence of peak current, base current, and frequency on the tensile strength of AA 6065 T6 aluminium alloy with varying thicknesses (3 mm, 6 mm, and 10 mm). Regression models are developed to predict tensile strength across the factorial space, and ANOVA is applied to assess the significance of each parameter. Experimental results identify optimal tensile strengths of 179.50 MPa, 188.92 MPa, and 201.22 MPa for 3 mm, 6 mm, and 10 mm thick materials, respectively, with process parameters set at 180 A peak current, 60 A base current, and 2 Hz frequency. Validation through simulation software corroborates these findings, confirming the effectiveness of the optimized parameters in producing defect-free, high-strength weld joints suitable for automotive applications. |
| format | Article |
| id | doaj-art-a57610900ee44bd4b2abadedd2a30716 |
| institution | OA Journals |
| issn | 2297-3079 |
| language | English |
| publishDate | 2025-05-01 |
| publisher | Frontiers Media S.A. |
| record_format | Article |
| series | Frontiers in Mechanical Engineering |
| spelling | doaj-art-a57610900ee44bd4b2abadedd2a307162025-08-20T02:26:19ZengFrontiers Media S.A.Frontiers in Mechanical Engineering2297-30792025-05-011110.3389/fmech.2025.15690591569059Optimization of welding strength in the tungsten inert gas welding process for aluminium alloysAmit Gupta0Rajeev Ranjan1Robert Cep2Ajay Kumar3Ajay Kumar4Sanjay Kumar Jha5Faisal Altarazi6Ashish Kumar7Namrata Dogra8Department of Mechanical Engineering, Sarala Birla University, Ranchi, IndiaDepartment of Mechanical Engineering, Sarala Birla University, Ranchi, IndiaDepartment of Machining, Assembly and Engineering Metrology, Faculty of Mechanical Engineering, VSB-Technical University of Ostrava, Ostrava, CzechiaDepartment of Mechanical Engineering, School of Core Engineering, Faculty of Science, Technology and Architecture, Manipal University, Jaipur, IndiaDepartment of Mechanical Engineering, School of Engineering and Technology, JECRC University, Jaipur, Rajasthan, IndiaDepartment of Production and Industrial Engineering, Birla Institute of Technology Mesra, Ranchi, Jharkhand, IndiaUniversity of Jeddah, Jeddah, Saudi ArabiaDivision of Research and Development, Lovely Professional University, Phagwara, IndiaDepartment of Orthodontics, Faculty of Dental Sciences, SGT University, Gurugram, Haryana, IndiaAluminium alloys, particularly AA 6065 T6, are widely used in automotive components such as coolers and radiators due to their excellent strength-to-weight ratio and corrosion resistance. However, welding these alloys presents significant challenges, as the weld joints are prone to thermal stresses, leading to defects and eventual failure. To address this issue, optimizing the PCTIG (Pulsed Current Tungsten Inert Gas) welding process parameters is crucial for achieving superior mechanical properties, particularly tensile strength. This study investigates the influence of peak current, base current, and frequency on the tensile strength of AA 6065 T6 aluminium alloy with varying thicknesses (3 mm, 6 mm, and 10 mm). Regression models are developed to predict tensile strength across the factorial space, and ANOVA is applied to assess the significance of each parameter. Experimental results identify optimal tensile strengths of 179.50 MPa, 188.92 MPa, and 201.22 MPa for 3 mm, 6 mm, and 10 mm thick materials, respectively, with process parameters set at 180 A peak current, 60 A base current, and 2 Hz frequency. Validation through simulation software corroborates these findings, confirming the effectiveness of the optimized parameters in producing defect-free, high-strength weld joints suitable for automotive applications.https://www.frontiersin.org/articles/10.3389/fmech.2025.1569059/fullTIG weldinguniversal testing machinefinite element methodANOVAregression analysis |
| spellingShingle | Amit Gupta Rajeev Ranjan Robert Cep Ajay Kumar Ajay Kumar Sanjay Kumar Jha Faisal Altarazi Ashish Kumar Namrata Dogra Optimization of welding strength in the tungsten inert gas welding process for aluminium alloys Frontiers in Mechanical Engineering TIG welding universal testing machine finite element method ANOVA regression analysis |
| title | Optimization of welding strength in the tungsten inert gas welding process for aluminium alloys |
| title_full | Optimization of welding strength in the tungsten inert gas welding process for aluminium alloys |
| title_fullStr | Optimization of welding strength in the tungsten inert gas welding process for aluminium alloys |
| title_full_unstemmed | Optimization of welding strength in the tungsten inert gas welding process for aluminium alloys |
| title_short | Optimization of welding strength in the tungsten inert gas welding process for aluminium alloys |
| title_sort | optimization of welding strength in the tungsten inert gas welding process for aluminium alloys |
| topic | TIG welding universal testing machine finite element method ANOVA regression analysis |
| url | https://www.frontiersin.org/articles/10.3389/fmech.2025.1569059/full |
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