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<p>This study aims to systematically investigate the superficial weld discontinuities that may occur after welding 1.75&#xa0;mm thick EN AW 5083 HO aluminum alloy sheets, known for their high corrosion resistance due to elevated magnesium content, using a butt joint configuration and the Gas Metal Arc Welding (GMAW) technique. The ultimate objective is to identify optimal welding parameters to enhance the structural integrity and service reliability of aluminum weldments, particularly for marine engineering applications. In the experimental phase, EN AW 5083 HO aluminum sheets were prepared and robotically welded using GMAW under varying welding currents and travel speeds. Following the welding process, non-destructive testing methods—including visual test (ISO 17637), liquid penetrant testing (ISO 3452–1), and radiographic examination (ISO 17636–1)—were conducted to detect surface and subsurface discontinuities. The acquired data were used to identify, categorize, and quantitatively assess weld imperfections such as porosity, incomplete fusion, bead irregularities, and surface cracking. A comprehensive analysis was conducted to evaluate the correlation between welding parameters and discontinuity occurrence, leading to the identification of the most effective parameter set for minimizing weld discontinuities. The results revealed a strong dependency of discontinuity formation on welding current and travel speed: elevated current and improper feed rates significantly increased porosity and fusion discontinuities. Conversely, the optimized parameter set substantially reduced surface discontinuity rates and improved overall weld bead quality. All findings were evaluated in accordance with the acceptance criteria defined in ISO 5817 for aluminum welds.</p>

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Investigation of surface welding discontinuities in EN AW 5083 HO aluminum plates joined by robotic GMAW butt welding using non-destructive testing methods

  • 期刊论文

  • 发表日期：

    2025年10月7日

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  • Celalettin Baykara,
  • Alaattin Oral

摘要

This study aims to systematically investigate the superficial weld discontinuities that may occur after welding 1.75 mm thick EN AW 5083 HO aluminum alloy sheets, known for their high corrosion resistance due to elevated magnesium content, using a butt joint configuration and the Gas Metal Arc Welding (GMAW) technique. The ultimate objective is to identify optimal welding parameters to enhance the structural integrity and service reliability of aluminum weldments, particularly for marine engineering applications. In the experimental phase, EN AW 5083 HO aluminum sheets were prepared and robotically welded using GMAW under varying welding currents and travel speeds. Following the welding process, non-destructive testing methods—including visual test (ISO 17637), liquid penetrant testing (ISO 3452–1), and radiographic examination (ISO 17636–1)—were conducted to detect surface and subsurface discontinuities. The acquired data were used to identify, categorize, and quantitatively assess weld imperfections such as porosity, incomplete fusion, bead irregularities, and surface cracking. A comprehensive analysis was conducted to evaluate the correlation between welding parameters and discontinuity occurrence, leading to the identification of the most effective parameter set for minimizing weld discontinuities. The results revealed a strong dependency of discontinuity formation on welding current and travel speed: elevated current and improper feed rates significantly increased porosity and fusion discontinuities. Conversely, the optimized parameter set substantially reduced surface discontinuity rates and improved overall weld bead quality. All findings were evaluated in accordance with the acceptance criteria defined in ISO 5817 for aluminum welds.