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<p>AA8011 and AA6061 alloys are particularly suited for applications in the aerospace, automotive, and packaging industries, where weight reduction, durability, and reliable mechanical performance are critically important. This study focuses on optimizing the input parameters and evaluating the output responses of AA8011 and AA6061 alloy joints fabricated using the cold metal transfer (CMT) welding process. These alloys were joined using filler ER4043, with a comprehensive microstructural and mechanical analysis conducted on the weldments. Microstructural observations revealed elongated grains in the partially melted zone (PMZ) and equiaxed dendritic at the weld fusion zone (WFZ), enhancing hardness and strength due to the absence of welding defects and effective dilution. The maximum ultimate tensile strength (UTS) of 109&#xa0;MPa was recorded for sample number 11, while the minimum UTS of 73&#xa0;MPa was observed for sample number 5. Enhanced hardness and UTS in the welded zone were attributed to the occurrence of a refined grain structure and delicate secondary phases in the WFZ. This work provides critical insights into the intricate correlation between input and output responses of the CMT welded joints of AA6061 and AA8011 dissimilar aluminum alloys. The findings underscore the importance of optimizing welding parameters to achieve superior mechanical properties and structural integrity in dissimilar aluminum alloy joints. The optimized input parameters, current, WS, and GFR were observed as 77.86 A, 9.26&#xa0;mm/s, and GFR of 15.26&#xa0;l/min, respectively. While optimized output value for tensile strength, % strain, hardness, and residual stress were observed 89.19&#xa0;MPa, 11.36, 78.88 HV, and − 36.47&#xa0;MPa, respectively.</p>

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Multi-Response Optimization of Process Parameters for Cold Metal Transfer Welded Joints of Dissimilar Alloys AA8011 and AA6061

  • 期刊论文

  • 发表日期：

    2025年7月1日

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  • Indra Jeet Singh,
  • Qasim Murtaza,
  • Paras Kumar

摘要

AA8011 and AA6061 alloys are particularly suited for applications in the aerospace, automotive, and packaging industries, where weight reduction, durability, and reliable mechanical performance are critically important. This study focuses on optimizing the input parameters and evaluating the output responses of AA8011 and AA6061 alloy joints fabricated using the cold metal transfer (CMT) welding process. These alloys were joined using filler ER4043, with a comprehensive microstructural and mechanical analysis conducted on the weldments. Microstructural observations revealed elongated grains in the partially melted zone (PMZ) and equiaxed dendritic at the weld fusion zone (WFZ), enhancing hardness and strength due to the absence of welding defects and effective dilution. The maximum ultimate tensile strength (UTS) of 109 MPa was recorded for sample number 11, while the minimum UTS of 73 MPa was observed for sample number 5. Enhanced hardness and UTS in the welded zone were attributed to the occurrence of a refined grain structure and delicate secondary phases in the WFZ. This work provides critical insights into the intricate correlation between input and output responses of the CMT welded joints of AA6061 and AA8011 dissimilar aluminum alloys. The findings underscore the importance of optimizing welding parameters to achieve superior mechanical properties and structural integrity in dissimilar aluminum alloy joints. The optimized input parameters, current, WS, and GFR were observed as 77.86 A, 9.26 mm/s, and GFR of 15.26 l/min, respectively. While optimized output value for tensile strength, % strain, hardness, and residual stress were observed 89.19 MPa, 11.36, 78.88 HV, and − 36.47 MPa, respectively.