TIG Welding of EN AW-6082 Al Alloy: A Comparative Analysis of Filler Rods on Microstructural and Mechanical Performance
This study investigates the impact of different filler wires (ER5356, ER4043, and ER4047) on the microstructural and mechanical properties of EN AW-6082 Al alloy joints produced by tungsten inert gas (TIG) welding. Butt-welded samples with a single V-groove joint configuration were prepared using op...
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2025-01-01
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| author | Bandar Alzahrani Mohamed M. Z. Ahmed Mohamed I. A. Habba Ramy A. Fouad Yousef G. Y. Elshaghoul Elshafey Ahmed Gadallah |
| author_facet | Bandar Alzahrani Mohamed M. Z. Ahmed Mohamed I. A. Habba Ramy A. Fouad Yousef G. Y. Elshaghoul Elshafey Ahmed Gadallah |
| author_sort | Bandar Alzahrani |
| collection | DOAJ |
| description | This study investigates the impact of different filler wires (ER5356, ER4043, and ER4047) on the microstructural and mechanical properties of EN AW-6082 Al alloy joints produced by tungsten inert gas (TIG) welding. Butt-welded samples with a single V-groove joint configuration were prepared using optimized welding parameters. The welded samples were subjected to visual inspection, microstructural analysis, hardness testing, tensile testing, and impact toughness evaluation. The results showed that all the welds were free of visible defects. Microstructural examination revealed that the ER5356 filler produced the finest grain structure of 18.03 ± 3 μm, while ER4047 resulted in the coarsest grains of 36.07 ± 5 μm. Correspondingly, the joints made with ER5356 exhibited the highest tensile stress of 278 ± 6 MPa, yield stress of 219 ± 5.4 MPa, hardness values of 72.7 ± 5 HV, and welding efficiency of 86.07%, whereas those made with ER4047 produced the lowest values. The hardness in the weld region was lower than that in the parent metal and heat-affected zone for all samples. However, ER4047 welds demonstrated superior impact toughness and strain-hardening capacity. The findings underscore the importance of filler metal selection in tailoring mechanical properties for high-performance applications. |
| format | Article |
| id | doaj-art-0d5315a790984b8cb7faed875404bf0f |
| institution | Kabale University |
| issn | 2504-4494 |
| language | English |
| publishDate | 2025-01-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Journal of Manufacturing and Materials Processing |
| spelling | doaj-art-0d5315a790984b8cb7faed875404bf0f2025-01-24T13:36:28ZengMDPI AGJournal of Manufacturing and Materials Processing2504-44942025-01-01912110.3390/jmmp9010021TIG Welding of EN AW-6082 Al Alloy: A Comparative Analysis of Filler Rods on Microstructural and Mechanical PerformanceBandar Alzahrani0Mohamed M. Z. Ahmed1Mohamed I. A. Habba2Ramy A. Fouad3Yousef G. Y. Elshaghoul4Elshafey Ahmed Gadallah5Mechanical Engineering Department, College of Engineering at Al-Kharj, Prince Sattam Bin Abdulaziz University, Al-Kharj 16273, Saudi ArabiaMechanical Engineering Department, College of Engineering at Al-Kharj, Prince Sattam Bin Abdulaziz University, Al-Kharj 16273, Saudi ArabiaMechanical Department, Faculty of Technology and Education, Suez University, Suez 43221, EgyptMechanical Department, Faculty of Technology and Education, Suez University, Suez 43221, EgyptMechanical Engineering Department, Faculty of Engineering, Suez University, Suez 43221, EgyptMechanical Department, Faculty of Technology and Education, Suez University, Suez 43221, EgyptThis study investigates the impact of different filler wires (ER5356, ER4043, and ER4047) on the microstructural and mechanical properties of EN AW-6082 Al alloy joints produced by tungsten inert gas (TIG) welding. Butt-welded samples with a single V-groove joint configuration were prepared using optimized welding parameters. The welded samples were subjected to visual inspection, microstructural analysis, hardness testing, tensile testing, and impact toughness evaluation. The results showed that all the welds were free of visible defects. Microstructural examination revealed that the ER5356 filler produced the finest grain structure of 18.03 ± 3 μm, while ER4047 resulted in the coarsest grains of 36.07 ± 5 μm. Correspondingly, the joints made with ER5356 exhibited the highest tensile stress of 278 ± 6 MPa, yield stress of 219 ± 5.4 MPa, hardness values of 72.7 ± 5 HV, and welding efficiency of 86.07%, whereas those made with ER4047 produced the lowest values. The hardness in the weld region was lower than that in the parent metal and heat-affected zone for all samples. However, ER4047 welds demonstrated superior impact toughness and strain-hardening capacity. The findings underscore the importance of filler metal selection in tailoring mechanical properties for high-performance applications.https://www.mdpi.com/2504-4494/9/1/21filling wireEN AW-6082 alloyTIG processmicrostructuremechanical behavior |
| spellingShingle | Bandar Alzahrani Mohamed M. Z. Ahmed Mohamed I. A. Habba Ramy A. Fouad Yousef G. Y. Elshaghoul Elshafey Ahmed Gadallah TIG Welding of EN AW-6082 Al Alloy: A Comparative Analysis of Filler Rods on Microstructural and Mechanical Performance Journal of Manufacturing and Materials Processing filling wire EN AW-6082 alloy TIG process microstructure mechanical behavior |
| title | TIG Welding of EN AW-6082 Al Alloy: A Comparative Analysis of Filler Rods on Microstructural and Mechanical Performance |
| title_full | TIG Welding of EN AW-6082 Al Alloy: A Comparative Analysis of Filler Rods on Microstructural and Mechanical Performance |
| title_fullStr | TIG Welding of EN AW-6082 Al Alloy: A Comparative Analysis of Filler Rods on Microstructural and Mechanical Performance |
| title_full_unstemmed | TIG Welding of EN AW-6082 Al Alloy: A Comparative Analysis of Filler Rods on Microstructural and Mechanical Performance |
| title_short | TIG Welding of EN AW-6082 Al Alloy: A Comparative Analysis of Filler Rods on Microstructural and Mechanical Performance |
| title_sort | tig welding of en aw 6082 al alloy a comparative analysis of filler rods on microstructural and mechanical performance |
| topic | filling wire EN AW-6082 alloy TIG process microstructure mechanical behavior |
| url | https://www.mdpi.com/2504-4494/9/1/21 |
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