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<p>This study investigates the formation of residual stresses, strains, and displacements in 5&#xa0;mm butt joints of aluminum alloy 1561 produced by metal inert gas (MIG), plasma arc welding (PAW), and hybrid PAW-MIG welding. At the same welding speed and comparable linear heat input, MIG produced the widest weld, whereas PAW produced the narrowest one; hybrid PAW-MIG formed a comparatively narrow weld with nearly equal upper and lower bead dimensions, which makes this process technologically advantageous. The use of a rigid fixture limited longitudinal and transverse shortening to ~ 0.5&#xa0;mm and caused only slight distortion of the unclamped zone (~ 0.4&#xa0;mm). Residual transverse stresses did not exceed 25&#xa0;MPa (&lt; 13&#xa0;MPa on the weld axis), whereas the average longitudinal residual stress on the weld axis, considering the face and reverse surfaces, was ~ 191&#xa0;MPa for MIG, ~ 179&#xa0;MPa for PAW-MIG, and ~ 214&#xa0;MPa for PAW. Rigid clamping minimized residual stresses and out-of-plane displacements for all methods; the smallest displacements were obtained with PAW, while the most favorable combination of weld geometry and residual stress level was achieved with hybrid PAW-MIG.</p>

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Formation of Residual Stresses, Strains, and Displacements in Butt Joints of Alloy 1561 During Arc, Plasma, and Hybrid Plasma-Arc Welding

  • 期刊论文

  • 发表日期：

    2026年6月18日

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  • Volodymyr Korzhyk,
  • Vladyslav Khaskin,
  • Viktor Kvasnytskyi,
  • Oleksandr Bushma,
  • Odarka Prokhorenko,
  • Shiyi Gao,
  • Andriy Alyoshin,
  • Andrii Perepichay,
  • Guirong,
  • Oksana Konoreva

摘要

This study investigates the formation of residual stresses, strains, and displacements in 5 mm butt joints of aluminum alloy 1561 produced by metal inert gas (MIG), plasma arc welding (PAW), and hybrid PAW-MIG welding. At the same welding speed and comparable linear heat input, MIG produced the widest weld, whereas PAW produced the narrowest one; hybrid PAW-MIG formed a comparatively narrow weld with nearly equal upper and lower bead dimensions, which makes this process technologically advantageous. The use of a rigid fixture limited longitudinal and transverse shortening to ~ 0.5 mm and caused only slight distortion of the unclamped zone (~ 0.4 mm). Residual transverse stresses did not exceed 25 MPa (< 13 MPa on the weld axis), whereas the average longitudinal residual stress on the weld axis, considering the face and reverse surfaces, was ~ 191 MPa for MIG, ~ 179 MPa for PAW-MIG, and ~ 214 MPa for PAW. Rigid clamping minimized residual stresses and out-of-plane displacements for all methods; the smallest displacements were obtained with PAW, while the most favorable combination of weld geometry and residual stress level was achieved with hybrid PAW-MIG.