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<p>To produce the desired weld properties using advanced welding technology, Cold Metal Transfer (CMT) welding process is used to join the dissimilar metals of AA6082 and AA7075 using ER2219 as filler wire. Taguchi-based Response Surface Methodology (RSM) technique is used for designing the experimental set-up parameter combination of 20 runs. The welding strength was evaluated by applying uni-axial loads using Universal Testing Machine (UTM) machine. The HAZ width of both the base metals were revealed using optical microscope. The maximum Ultimate Tensile Strength (UTS) value of 236&#xa0;MPa with Yield Strength (YS) value of 140&#xa0;MPa was observed in sample 12 when welding current is higher with moderate welding speed. Also, the HAZ width was observed to be lower when higher welding speed with lower welding current employed. The generated model is suggested that increasing feed rates along with higher welding speeds decreases the HAZ width of both the base metals. RSM model suggesting that the optimal current value is 133.18&#xa0;A is closer to the lower boundary of the analysed range. The optimal feed rate is 5.7305&#xa0;m/min, falls within the mid to high spectrum of the evaluated values. The welding speed is maximized at 568.18&#xa0;mm/min, at the upper limit of the investigated range. Increased welding speeds decrease the duration of material exposure to heat, thereby reducing the width of the HAZ. This research will particularly help the aerospace sector in choosing appropriate parameters for the CMT welding process in order to improve the quality of welded structures.</p> Graphical Abstract <p></p>

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Optimization of cold metal transfer welding process parameters for development of AA6082 and AA7075 dissimilar weldments: RSM technique

  • 期刊论文

  • 发表日期：

    2025年8月29日

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  • Chilakamarri L Aslesha,
  • Kali Charan Rath,
  • Vishnu Vardhan T

摘要

To produce the desired weld properties using advanced welding technology, Cold Metal Transfer (CMT) welding process is used to join the dissimilar metals of AA6082 and AA7075 using ER2219 as filler wire. Taguchi-based Response Surface Methodology (RSM) technique is used for designing the experimental set-up parameter combination of 20 runs. The welding strength was evaluated by applying uni-axial loads using Universal Testing Machine (UTM) machine. The HAZ width of both the base metals were revealed using optical microscope. The maximum Ultimate Tensile Strength (UTS) value of 236 MPa with Yield Strength (YS) value of 140 MPa was observed in sample 12 when welding current is higher with moderate welding speed. Also, the HAZ width was observed to be lower when higher welding speed with lower welding current employed. The generated model is suggested that increasing feed rates along with higher welding speeds decreases the HAZ width of both the base metals. RSM model suggesting that the optimal current value is 133.18 A is closer to the lower boundary of the analysed range. The optimal feed rate is 5.7305 m/min, falls within the mid to high spectrum of the evaluated values. The welding speed is maximized at 568.18 mm/min, at the upper limit of the investigated range. Increased welding speeds decrease the duration of material exposure to heat, thereby reducing the width of the HAZ. This research will particularly help the aerospace sector in choosing appropriate parameters for the CMT welding process in order to improve the quality of welded structures.

Graphical Abstract