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<p>This study investigates the influence of filler metal selection on the microstructure and mechanical behavior of TIG-welded AA6061-T6 aluminum alloy using two different filler metals, ER4043 (Al–Si) and ER5183 (Al–Mg). SEM analysis of the BM reveals a microstructure predominantly composed of α-Al grains with precipitates dispersed along grain boundaries and within the grains. In the HAZ zone, phenomena such as dissolution, over-aging, and coalescence of precipitates occur, leading to the loss of their hardening effects and changes in material properties. SEM images illustrate the eutectic structure of the molten zone, highlighting dendritic structures and equiaxed grains in the welded assemblies. Microhardness profiles revealed significant softening in the heat-affected zone and lower hardness in the molten zone of ER4043-welded joints compared to ER5183 ones. Tensile tests showed a reduction in strength and fracture in the heat-affected zone for both weldments, with high overall mechanical performance recorded using ER5183 filler metal. Charpy impact tests confirmed that the ER5183 molten zone exhibited the highest impact toughness and ductility. The results underscore the critical role of filler metal in optimizing weld properties for aluminum alloys.</p>

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Effect of filler metal nature on microstructure and mechanical properties of Al-6061 TIG-weld joint

  • 期刊论文

  • 发表日期：

    2025年7月24日

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  • Maamar Hakem,
  • Leila Belgacem,
  • Naima Ouali,
  • Bouzid Maamache,
  • Jaime Viña,
  • Miguel Lozano,
  • Brahim Belkessa,
  • Billel Cheniti

摘要

This study investigates the influence of filler metal selection on the microstructure and mechanical behavior of TIG-welded AA6061-T6 aluminum alloy using two different filler metals, ER4043 (Al–Si) and ER5183 (Al–Mg). SEM analysis of the BM reveals a microstructure predominantly composed of α-Al grains with precipitates dispersed along grain boundaries and within the grains. In the HAZ zone, phenomena such as dissolution, over-aging, and coalescence of precipitates occur, leading to the loss of their hardening effects and changes in material properties. SEM images illustrate the eutectic structure of the molten zone, highlighting dendritic structures and equiaxed grains in the welded assemblies. Microhardness profiles revealed significant softening in the heat-affected zone and lower hardness in the molten zone of ER4043-welded joints compared to ER5183 ones. Tensile tests showed a reduction in strength and fracture in the heat-affected zone for both weldments, with high overall mechanical performance recorded using ER5183 filler metal. Charpy impact tests confirmed that the ER5183 molten zone exhibited the highest impact toughness and ductility. The results underscore the critical role of filler metal in optimizing weld properties for aluminum alloys.