In this article, parameters of Double-Pulse Metal Inert Gas Welding (DP-MIG) was used for minimising a porosity formation in a T-joint fillet weld. AA5083-H112 aluminium alloy (Non-heat treatable series) with the plate thickness of 10 millimetres is base metal for this study. Welding consumables were filler wire ER5356 with a diameter of 1.2 millimetres and shielded by industrial argon gas. Three majorities parameter of DP-MIG were Delta wire feed (m/min), Frequency (Hz) and Duty cycle (%). Measurable signal current pattern and opened porosity on the fractured surface were couple observed to study their relationships. An appropriate image processing technique was employed to quantitative measuring and calculating a size grouping area of several opened porosities overall weld length, precisely. The result found that the optimal was used a low-level of Delta wire feed of 0.8 m/min, a high-level of a frequency of 5.0 Hz, a mid-level of the duty cycle 30 % and a high travel speed 60 cm/min could minimise the porosity formation with complete penetration.
The study of the effects of cooling conditions on mechanical properties and wear performance by coating AISI S45C steel with Chrome Nickel Amorphous wire arc spray showed that the average surface hardness of specimens under different cooling conditions such as SCCW, SCCO, SCCS and SCCNT was 601.6 HV, while the surface hardness of HAZ of SCCS and SCCW specimens decreased to 80-90 HV. The tensile test revealed that the average ultimate tensile strength of coated specimens was 706 MPa which was slightly higher than that of uncoated specimens. This result is consistent with Tukey’s one-way ANOVA method, which found a significant difference in tensile strength values at 0.05 and 0.01 levels. For wear resistance, coated specimens showed higher wear resistance compared to uncoated specimens. Overall, the results of this study showed that wire arc spray coating could increase the strength and stress and decrease %elongation of the specimens. Therefore, this technique is suitable for maintenance work to increase the strength of steel in the industry.
In this study, MIG welding parameters were optimized by experts. The results showed that heat input affected the welding of all five specimens, and similar structural changes were observed. The part adjacent to the weld line, using low HI (BM) lower than the melting point, increased the grain size and decreased the average hardness (87 HV) at HAZ. In comparison, high HI (WZ) at melting point resulted in fine grain with a high hardness of 126.8 HV and tensile strength of 686 MPa. Nevertheless, fatigue testing revealed that the specimens suffered a brittle fracture under a slight load cycle of 104 Nf. Correlation analysis of HI, mechanical properties and optimization plot revealed the optimum HI of 363 J/mm, and the verification by fatigue testing showed the optimum load cycle of 106 Nf. However, the determination of maximum strength should be done using several techniques for more effective improvement of quality and yield using the research findings of this study.
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