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<p>The analysis in this study focuses on the butt metal inert gas (MIG) welding of 2.5-mm-thick 6063-T6 aluminum alloy plates, and employs a numerical simulation approach to investigate the influence of MIG welding current on the flow behavior of the molten pool (MP). The increase in welding current is correlated with the metal flow within the MP. At lower welding currents, the MP exhibits a single circulation pattern, whereas at higher currents, multiple circulations are observed. The optimal macroscopic weld appearance is achieved at a welding current of 85&#xa0;A. The formation of equiaxed crystals is observed in the weld metal zone (WMZ). As the welding current increases, the grain structure in the WMZ transitions from fine equiaxed grains to coarse equiaxed grains, while the proportion of high-angle grain boundaries first increases and then decreases, reaching its maximum at a welding current of 85&#xa0;A.</p>

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Effect of Welding Current on Molten Pool Dynamics and Microstructure in MIG Welding of 6063-T6 Aluminum Alloy

  • 期刊论文

  • 发表日期：

    2025年8月25日

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  • Shuwan Cui,
  • Xiaozhen Liu,
  • Weilin Zhang,
  • Ganli Mo,
  • Hongchen Li,
  • Hao Li

摘要

The analysis in this study focuses on the butt metal inert gas (MIG) welding of 2.5-mm-thick 6063-T6 aluminum alloy plates, and employs a numerical simulation approach to investigate the influence of MIG welding current on the flow behavior of the molten pool (MP). The increase in welding current is correlated with the metal flow within the MP. At lower welding currents, the MP exhibits a single circulation pattern, whereas at higher currents, multiple circulations are observed. The optimal macroscopic weld appearance is achieved at a welding current of 85 A. The formation of equiaxed crystals is observed in the weld metal zone (WMZ). As the welding current increases, the grain structure in the WMZ transitions from fine equiaxed grains to coarse equiaxed grains, while the proportion of high-angle grain boundaries first increases and then decreases, reaching its maximum at a welding current of 85 A.