The Mechanical Properties of 6061-T6 Aluminum Alloy Joints Joined by MIG Welding Method (TPS/i) Using Different Shielding Gas Flow Rates
Year 2025,
Volume: 29 Issue: 3, 272 - 284, 26.06.2025
Erman Ferik
,
Sedat Dağlaraştı
,
Faruk Varol
Abstract
In this study, aluminum 6061-T6 alloy sheets with a thickness of 3 millimeters were welded using the TPS/i MIG welding process. Welded samples were joined in the shape of butt joints. Argon was used as the welding shield gas, and the welded joint procedures were carried out at various shielding gas flow rates. Tensile strength and hardness values of the welded 6061-T6 aluminum alloy sheets were determined, and their microstructure and macrostructure were investigated using an optical microscope. The weldability of 6061-T6 aluminum sheets was investigated using the MIG welding process (TPS/i), and the impact of various shielding gas flow rates on mechanical parameters, macrostructures, and microstructures was studied.
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- Z. Shen, R. H. Wagoner, W. A. T. Clark, “Dislocation and grain boundary interactions in metals,” Acta Metallurgica, vol. 36, no. 12, pp. 3231-3242, 1988.
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- S. Yang, X. Yang, X. Lu, M. V. Li, H. Zuo, Y. Wang, “Strength calculation and microstructure characterization of haz softening area in 6082-T6 aluminum alloy CMT welded joints,” Materials Today Communications, vol. 37, 107077, 2023.
- M. Zhu, S. Yang, Y. Bai, C. Fan, “Uneven hardness mechanism and related fracture characteristics in laser-MIG hybrid welded Al–Mg–Si alloy butt,” Journal of Laser Applications, vol. 33, no. 4, pp. 42-54, 2021.
- M. A. Van Huis, J. H. Chen, H. W. Zandbergen, M. H. F. Sluiter, “Phase stability and structural relations of nanometer-sized, matrix-embedded precipitate phases in Al–Mg–Si alloys in the late stages of evolution,” Acta Materialia, vol. 54, no. 11, pp. 2945-2955, 2006.
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- Z. Yang, I. Erdle, C. Liu, J. Banhart, “Clustering and precipitation in Al-Mg-Si alloys during linear heating,” Journal of Materials Science & Technology, vol. 120, pp. 78-88, 2022.
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- Z. Yang, I. Erdle, C. Liu, J. Banhart, “Clustering and precipitation in Al-Mg-Si alloys during linear heating,” Journal of Materials Science & Technology, vol. 120, pp. 78-88, 2022.
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- J. A. Vargas, J. E. Torres, J. A. Pacheco, R. J. Hernandez, “Analysis of heat input effect on the mechanical properties of Al-6061-T6 alloy weld joints,” Materials & Design (1980-2015), vol. 52, pp. 556-564, 2013.
- M. V. Kumar, V. Balasubramanian, S. Rajakumar, S. K. Albert, “Stress corrosion cracking behaviour of gas tungsten arc welded super austenitic stainless steel joints,” Defence Technology, vol. 11, no. 3, pp. 282-291, 2015.
Year 2025,
Volume: 29 Issue: 3, 272 - 284, 26.06.2025
Erman Ferik
,
Sedat Dağlaraştı
,
Faruk Varol
References
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- K. Anderson, J. Weritz, J. G. Kaufman (eds.), ASM Handbook Volume 2A - Aluminum Science and Technology, Ohio: ASM International, 2018.
- Z. Fang, J. Cao, Y. Guan, Corrosion Control Technologies for Aluminum Alloy Vessel, Singapore: Springer, 2020.
- H. Abramovich, Advanced Aerospace Materials: Aluminum-Based and Composite Structures, 2nd ed. Berlin: Walter de Gruyter GmbH, 2023.
- H. Liu, J. Li, Z. Ma, B. Ma, S. Feng, “Study on mechanical properties and microstructure analysis of welded joints of 7A05 aluminum alloy by laser-MIG hybrid welding,” In 2nd International Conference on Electronic & Mechanical Engineering and Information Technology, France: Atlantis Press, 2012, pp. 1465-1470.
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- J. R. Davis, Aluminum and Aluminum Alloys, Ohio: ASM International, 1999.
- L. F. Mondolfo, Aluminum Alloys: Structure and Properties, London: Butterworth-Heinemann, 1976.
- The Aluminum Association, Aluminum Design Manual, Specifications & Guidelines for Aluminum Structures, 8th ed. Washington: The Aluminum Association, Inc, 2005.
- G. E. Totten, D. S. MacKenzie, Handbook of Aluminum: Volume 2: Alloy Production and Materials Manufacturing, New York: Marcel Dekker Inc, 2003.
- J. G. Kaufman, Introduction to Aluminum Alloys and Tempers, Ohio: ASM International, 2000.
- J. R., Kissell, R. L. Ferry, Aluminum Structures: A Guide to Their Specifications and Design, 2nd ed. New York: John Wiley & Sons, 2002.
- H. J. McQueen, S. Spigarelli, M. Kassner, E. Evangelista, Hot Deformation and Processing of Aluminum Alloys, Boca Raton: CRC Press, 2016.
- D. Luo, Y. Xiao, L. Hardwick, R. Snell, M. Way, X. S. Morell, F. Livera, N. Ludford, C. Panwisawas, H. Dong, R. Goodall, “High entropy alloys as filler metals for joining,” Entropy, vol. 23, no. 1, pp. 78-101, 2021.
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- D. H. Phillips, Welding Engineering An Introduction, 2nd ed. New Jersey: John Wiley & Sons, Inc., 2023.
- N. Kahraman, B. Gülenç, Modern Kaynak Teknolojisi ve Kaynak İşlerinde İş Sağlığı ve Güvenliği, Genişletilmiş 4. Baskı. Epa-Mat Basım Yayın Ltd, Şti: Ankara, 2020.
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- A. Çelik, Kaynak Teknolojileri, Ankara: Nobel Akademik Yayıncılık, 2020.
- S. E. Hughes, A Quick Guide to Welding and Weld Inspection, Cambridge: Woodhead Publishing, 2009.
- R. L. O’Brien, Welding Handbook. Volume 2: Welding Processes: Part 1, 9th ed. Miami: American Welding Society, 2004.
- K. Weman, G. Lindén, (eds.), MIG Welding Guide, Cambridge: Woodhead Publishing, 2006.
- T. Anderson, Welding Aluminum: Questions and Answers: A Practical Guide for Troubleshooting Aluminum Welding-related Problems, 2nd ed. Miami: American Welding Society, 2010.
- Fronius International Gmbh. (2025.05.20) TransSynergic 4000/5000, TransPuls Synergic 2700, TransPuls Synergic 3200/4000/5000, TIME 5000 Digital, CMT 4000 Advanced Kullanım Kılavuzu [Online]. Available: https://www.alganmetal.com.tr/images/gallery_files/74814ts_tps_kullanim_kilavuzu_yeni.pdf
- K. R. Madavi, B. F. Jogi, G. S. Lohar, “Metal Inert Gas (MIG) Welding Process: A Study of Effect of Welding Parameters,” Materials Today: Proceedings, vol 51, pp. 690-698, 2022.
- G. M. Evans, N. Bailey, Metallurgy of Basic Weld Metal, Cambridge: Woodhead Publishing Limited, 1997.
- K. Badwal, P. Khanna, “Investigation of effect of shielding gases on angular distortion and bead profile parameters of MIG welded stainless steel 409L plates,” Materials Today: Proceedings, vol 56, pp. 645-649, 2022.
- Z. H. Rao, J. Hu, S. M. Liao, H. L. Tsai, “Study the shielding gas effect on the metal transfer and weld pool dynamics in GMAW,” In Heat Transfer Summer Conference, California, USA, vol. 43581, 2009, pp. 675-684.
C. Cai, S. He, H. Chen, W. Zhang, “The influences of Ar-He shielding gas mixture on welding characteristics of fiber laser-MIG hybrid welding of aluminum alloy,” Optics & Laser Technology, vol. 113, pp. 37-45, 2019.
- S. W. Campbell, A. M. Galloway, G. M. Ramsey, N. A. McPherson, “A potential solution to GMAW gas flow optimisation,” In Trends in Welding Research 2012: Proceedings of the 9th International Conference, Chicago, USA, pp. 453-460, 2012.
- G. D. Uttrachi, “GMAW shielding gas flow control systems,” Welding Journal, vol. 86, no. 4, pp. 22-23, 2007.
- S. W. Campbell, A. M. Galloway, N. A. McPherson, “Techno-economic evaluation of reducing shielding gas consumption in GMAW whilst maintaining weld quality,” The International Journal of Advanced Manufacturing Technology, vol. 63, pp. 975-985, 2012.
- W. Lucas, S. Westgate, “Welding and Soldering,” in Electrical Engineer’s Reference Book, M. A. Laughton, D. J. Warne Eds. Oxford: Elsevier Science, pp. 246-298, 2003.
- C. Rajendran, T. Sonar, M. Ivanov, C. Sandeep, C. Shanthi, N. K. Gurajala, K. Balachandar, J. Xu, “Enhancing tensile properties of pulsed CMT–MIG welded high strength AA2014-T6 alloy joints: effect of post weld heat treatment,” International Journal of Lightweight Materials and Manufacture, vol. 7, no. 2, pp. 344-352, 2024.
- Z. Ye, H. Zhu, S. Wang, W. Wang, J. Yang, J. Huang, “Fabricate high-strength 7075 aluminum alloy joint through double pulse MIG welding process,” Journal of Manufacturing Processes, vol. 125, pp. 512-522, 2024.
- V. Singh, Q. Murtaza, M. S. Niranjan, “Microstructure and mechanical properties of CMT welded AA6063-T6/B4C/ES metal matrix composite using ER5356 filler wire,” Materials Today: Proceedings, 2024.
- S. T. Selvamani, “Microstructure and stress corrosion behaviour of CMT welded AA6061 T-6 aluminium alloy joints,” Journal of Materials Research and Technology, vol. 15, pp. 315-326, 2021.
- Z. Shen, R. H. Wagoner, W. A. T. Clark, “Dislocation and grain boundary interactions in metals,” Acta Metallurgica, vol. 36, no. 12, pp. 3231-3242, 1988.
- M. P. Anderson, D. J. Srolovitz, G. S. Grest, P. S. Sahni, “Computer simulation of grain growth—I. kinetics,” Acta Metallurgica, vol. 32, no. 5, pp. 783-791, 1984.
- S. Yang, X. Yang, X. Lu, M. V. Li, H. Zuo, Y. Wang, “Strength calculation and microstructure characterization of haz softening area in 6082-T6 aluminum alloy CMT welded joints,” Materials Today Communications, vol. 37, 107077, 2023.
- M. Zhu, S. Yang, Y. Bai, C. Fan, “Uneven hardness mechanism and related fracture characteristics in laser-MIG hybrid welded Al–Mg–Si alloy butt,” Journal of Laser Applications, vol. 33, no. 4, pp. 42-54, 2021.
- M. A. Van Huis, J. H. Chen, H. W. Zandbergen, M. H. F. Sluiter, “Phase stability and structural relations of nanometer-sized, matrix-embedded precipitate phases in Al–Mg–Si alloys in the late stages of evolution,” Acta Materialia, vol. 54, no. 11, pp. 2945-2955, 2006.
- J. H. Chen, E. Costan, M. A. Van Huis, Q. Xu, H. W. Zandbergen, “Atomic pillar-based nanoprecipitates strengthen AlMgSi alloys,” Science, vol. 312, no. 5772, pp. 416-419, 2006.
- C. D. Marioara, H. Nordmark, S. J. Andersen, R. Holmestad, “Post-β″ phases and their influence on microstructure and hardness in 6xxx Al-Mg-Si alloys,” Journal of Materials Science, vol. 41, pp. 471-478, 2006.
- H. Liu, S. Yang, C. Xie, Q. Zhang, Y. Cao, “Microstructure characterization and mechanism of fatigue crack initiation near pores for 6005A CMT welded joint,” Materials Science and Engineering: A, vol. 707, pp. 22-29, 2017.
- Z. Yang, I. Erdle, C. Liu, J. Banhart, “Clustering and precipitation in Al-Mg-Si alloys during linear heating,” Journal of Materials Science & Technology, vol. 120, pp. 78-88, 2022.
- X. Xu, W. Zhu, X. Guo, C. Liang, Y. Deng, “Effect of ageing treatment process on the microstructure development and mechanical properties of 6082 Al alloy,” Journal of Alloys and Compounds, vol. 935, no. 1, 167892, 2023.
- S. Yang, Y. Wang, X. Yang, X. Lu, M. V. Li, X. Zhu, “Effect of softening of 6082-T6 aluminum alloy CMT welded joints on mechanical properties and fracture behavior,” Journal of Manufacturing Processes, vol. 124, pp. 1567-1582, 2024.
- I. Guzmán, E. Granda, B. Vargas, C. Cruz, Y. Avila, J. Acevedo, “Tensile and fracture behavior in 6061-T6 and 6061-T4 aluminum alloys welded by pulsed metal transfer GMAW,” The International Journal of Advanced Manufacturing Technology, vol. 103, pp. 2553-2562, 2019.
- Z. Yang, I. Erdle, C. Liu, J. Banhart, “Clustering and precipitation in Al-Mg-Si alloys during linear heating,” Journal of Materials Science & Technology, vol. 120, pp. 78-88, 2022.
- Q. T. Wang, X. N. Wang, X. M. Chen, P. C. Huan, Q. P. Dong, Q. Y. Zhang, H. Nagaumi, “Interactive effects of porosity and microstructure on strength of 6063 aluminum alloy CMT MIX+ Synchropulse welded joint,” Transactions of Nonferrous Metals Society of China, vol 32, no. 3, pp. 801-811, 2022.
- J. A. Vargas, J. E. Torres, J. A. Pacheco, R. J. Hernandez, “Analysis of heat input effect on the mechanical properties of Al-6061-T6 alloy weld joints,” Materials & Design (1980-2015), vol. 52, pp. 556-564, 2013.
- M. V. Kumar, V. Balasubramanian, S. Rajakumar, S. K. Albert, “Stress corrosion cracking behaviour of gas tungsten arc welded super austenitic stainless steel joints,” Defence Technology, vol. 11, no. 3, pp. 282-291, 2015.