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<p>Welding of dissimilar alloys is challenging due to differences in their physical and chemical properties. The main problem while joining dissimilar alloys is intermetallic compound (IMC) formation, which affects the weld quality. Controlling the heat input is necessary to minimize the formation of IMC. This work uses cold metal transfer (CMT) welding with low heat input. However, the application of CMT welding is limited to thin sheets due to low depth of penetration (DOP). Activated flux can improve the performance of CMT welding, thus improving the DOP and minimizing the weld width (WW) by arc constrict mechanism. In this investigation, the SiO<sub>2</sub> was used as an activated flux. The process parameters used in this study are welding current and welding speed, which were used to optimize tensile strength, hardness, DOP/WW ratio, and heat input. Numerous experiments were conducted as per the design of experiment using response surface methodology. The optimal input parameters from various experiments are a welding current of 150 A and a welding speed of 8.295 mm/s. The scanning electron microscope was used to analyze the microstructure of weld specimens. Energy dispersive spectroscopy and X-ray diffraction were used for elements and phase analysis.</p>

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Influence of activated flux on the mechanical and microstructural response of cold metal transfer welded AA6063-MgAZ31B dissimilar alloy

  • 期刊论文

  • 发表日期：

    2025年4月15日

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  • Abhi Bansal,
  • S. C. Vettivel,
  • Mukesh Kumar

摘要

Welding of dissimilar alloys is challenging due to differences in their physical and chemical properties. The main problem while joining dissimilar alloys is intermetallic compound (IMC) formation, which affects the weld quality. Controlling the heat input is necessary to minimize the formation of IMC. This work uses cold metal transfer (CMT) welding with low heat input. However, the application of CMT welding is limited to thin sheets due to low depth of penetration (DOP). Activated flux can improve the performance of CMT welding, thus improving the DOP and minimizing the weld width (WW) by arc constrict mechanism. In this investigation, the SiO2 was used as an activated flux. The process parameters used in this study are welding current and welding speed, which were used to optimize tensile strength, hardness, DOP/WW ratio, and heat input. Numerous experiments were conducted as per the design of experiment using response surface methodology. The optimal input parameters from various experiments are a welding current of 150 A and a welding speed of 8.295 mm/s. The scanning electron microscope was used to analyze the microstructure of weld specimens. Energy dispersive spectroscopy and X-ray diffraction were used for elements and phase analysis.