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<p>This study explores the process optimization of response surface methodology (RSM) on tungsten inert gas (TIG) welding to join 3 mm thick 5083 aluminum alloy sheets. The tungsten electrode height (TEH), welding current and welding speed were the key factors, and tensile strength and microhardness were the response variables. A multiple regression model was developed to establish the relationship between the influencing factors and response variables. According to the analysis of variance (ANOVA), the regression model exhibited high accuracy, showing that the welding current and welding speed were the most significant parameters affecting tensile strength and microhardness, respectively. Importantly, if the multifactor interactions were taken account, TEH was the most critical parameter. Based on the analysis, experiments were carried out on the aluminum alloys by TIG at different TEH. Microstructural characterization of the weld joints and mechanical properties were investigated. Specifically, 259.4&#xa0;MPa strength and 65.1&#xa0;HV<sub>0.1</sub> microhardness were achieved at TEH = 4 mm due to the solid solution structured weld with minimal defects and the weld joint exhibited the ductile fracture. Based on both experimental measurements and modeling prediction, the reliability of RSM was verified by a practical TIG weld on 5083 aluminum alloy, showing the best mechanical performance of tensile strength (268.758&#xa0;MPa) and microhardness (66.516&#xa0;HV<sub>0.1</sub>).</p>

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Influence of Tungsten Electrode Heights on Microstructure and Mechanical Properties of TIG-Welded 5083 Al Alloy via a Process Optimization by Response Surface Methodology

  • 期刊论文

  • 发表日期：

    2025年10月9日

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  • Yonglin Zhao,
  • Xincheng Zhao,
  • Han Li,
  • Jun Yang,
  • Bingyuan Han,
  • Yuxiang Liu

摘要

This study explores the process optimization of response surface methodology (RSM) on tungsten inert gas (TIG) welding to join 3 mm thick 5083 aluminum alloy sheets. The tungsten electrode height (TEH), welding current and welding speed were the key factors, and tensile strength and microhardness were the response variables. A multiple regression model was developed to establish the relationship between the influencing factors and response variables. According to the analysis of variance (ANOVA), the regression model exhibited high accuracy, showing that the welding current and welding speed were the most significant parameters affecting tensile strength and microhardness, respectively. Importantly, if the multifactor interactions were taken account, TEH was the most critical parameter. Based on the analysis, experiments were carried out on the aluminum alloys by TIG at different TEH. Microstructural characterization of the weld joints and mechanical properties were investigated. Specifically, 259.4 MPa strength and 65.1 HV0.1 microhardness were achieved at TEH = 4 mm due to the solid solution structured weld with minimal defects and the weld joint exhibited the ductile fracture. Based on both experimental measurements and modeling prediction, the reliability of RSM was verified by a practical TIG weld on 5083 aluminum alloy, showing the best mechanical performance of tensile strength (268.758 MPa) and microhardness (66.516 HV0.1).