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<p>This study optimizes process parameters and evaluates the mechanical properties and microstructural analysis of CMT-welded joints of dissimilar alloys of AA6061 and AA8011. Welding was performed using ER4043 filler wire, followed by a comprehensive characterization of the weldments to establish the correlation between mechanical properties and microstructure. Detailed metallographic analysis revealed elongated grains within the partially melted zone (PMZ) and fine, equiaxed dendritic structures in the weld fusion zone (WFZ). These microstructural features improved hardness and tensile strength, primarily due to the defect-free weld formation and effective material mixing under optimized CMT conditions. X-ray diffraction (XRD) analysis confirmed the formation of intermetallic compounds (IMCs), particularly Mg<sub>2</sub>Si and Al<sub>13</sub>Fe<sub>4</sub>. Mechanical testing demonstrated that at a welding current of 100 A, welding speed of 12&#xa0;mm/s, and gas flow rate of 14&#xa0;l/min, the highest ultimate tensile strength (UTS) was 117.84&#xa0;MPa, whereas at a welding current of 90 A, welding speed of 12&#xa0;mm/s, and gas flow rate of 16&#xa0;l/min, the lowest value was 68.92&#xa0;MPa. The enhanced mechanical performance is attributed to refined grain structures and uniformly dispersed strengthening phases in the WFZ.</p>

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Optimization of Process Parameters and Microstructural Analysis of CMT Welded Joints of Dissimilar Aluminum Alloys

  • 期刊论文

  • 发表日期：

    2025年10月16日

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

摘要

This study optimizes process parameters and evaluates the mechanical properties and microstructural analysis of CMT-welded joints of dissimilar alloys of AA6061 and AA8011. Welding was performed using ER4043 filler wire, followed by a comprehensive characterization of the weldments to establish the correlation between mechanical properties and microstructure. Detailed metallographic analysis revealed elongated grains within the partially melted zone (PMZ) and fine, equiaxed dendritic structures in the weld fusion zone (WFZ). These microstructural features improved hardness and tensile strength, primarily due to the defect-free weld formation and effective material mixing under optimized CMT conditions. X-ray diffraction (XRD) analysis confirmed the formation of intermetallic compounds (IMCs), particularly Mg2Si and Al13Fe4. Mechanical testing demonstrated that at a welding current of 100 A, welding speed of 12 mm/s, and gas flow rate of 14 l/min, the highest ultimate tensile strength (UTS) was 117.84 MPa, whereas at a welding current of 90 A, welding speed of 12 mm/s, and gas flow rate of 16 l/min, the lowest value was 68.92 MPa. The enhanced mechanical performance is attributed to refined grain structures and uniformly dispersed strengthening phases in the WFZ.