Pulsed TIG Welding of Al–SiC Composite: Welding Parameter Optimization

Abstract

Pulse on time, pulse frequency, peak current, and base current are the important parameters to be optimized in pulsed current tungsten inert gas (PCTIG) welding of Al–SiC metal matrix composite. Experiments were designed and conducted using the L9 orthogonal array technique. The regression equation was developed using Design Expert® statistical software package to predict the weld center’s micro hardness, yield strength, ultimate strength, elongation (%), bending load, weld depth, weld width, cooling rate, and peak temperature near the weld zone of Al-8% SiC composite, welded using PCTIG welding. Correlation coefficient shows 0.9 for all the mechanical properties. This showed that the regression equation and the mathematical model developed were adequate. Analysis of contour plot, interaction effect, signal-to-noise ratio, and mean response were developed, the influence of each pulsed current parameter was evaluated at each level, and the percentage of influence was calculated by using pulsed current parameters. Ultimate tensile strength and bending load values depend on the microstructure. When the cooling rate is higher, fine microstructures are observed due to grain refinement; higher tensile strength and bending load are also observed. Due to the decreased cooling rate, coarse microstructures are observed, which result in poor tensile strength and bending load. PCTIG welding parameters are responsible for the change in the cooling rate of the weld zone. The optimization of the PCTIG welding parameters shows that the peak current and base current should be 160 and 60 A, respectively. Pulse on time is recommended to be 50%–55% and pulse frequency to be 5 Hz.