Effect of Double Pulse MIG Welding on Porosity Formation on Aluminium 5083 Fillet Joint

Abstract

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.

Studies on Quality of Joints and Phenomena Therein for Welded Vehicle Components Made of Aluminium Alloy – a Review

“…The conventional MIG welding is characterized by an unstable arc, insufficient heat input and small penetration depth [5]. These problems can be resolved with the pulse-MIG welding technique based on pulsed current waveform allowing precise control of the metal transfer rate [164], applicable for 6061/A356 alloys joining or 5083 alloy joints [165].…”

Studies on the Quality of Joints and Phenomena Therein for Welded Automotive Components Made of Aluminum Alloy—A Review

“…Conventional MIG welding is characterized by an unstable arc, insufficient heat input, and small penetration depth [5]. These problems can be resolved with the pulsed MIG welding technique based on a pulsed current waveform, allowing for the precise control of the metal transfer rate [165], which is applicable to 6061/A356 or 5083 alloy joints [166].…”