Study of Weld Bead Geometry and Optimization of Cold Metal Transfer (CMT) Process Parameters for Fabrication of AA6082 by Using Activated Flux

The aerospace, defense, and automobile industries recognize the potential of aluminum alloys due to their high strength-to-weight ratio and structural integrity. However, manufacturers face challenges when it comes to fusion welding dissimilar aluminum alloys. In this research, the focus was on fabricating weld beads using the cold metal transfer process, specifically using aluminum alloy 4043 on an aluminum 6082 base plate. The objective was to optimize the selection of parameters to achieve the desired bead geometry while minimizing issues like incomplete weld beads, weld cracks, and waviness. The study aimed to investigate the effects of two input process parameters, namely current and welding speed, at three different levels on three properties: dilution, microhardness, and penetration depth. Taguchi optimization technique was utilized to determine the optimal parameters, and the adequacy of the model was assessed through ANOVA analysis. The results indicated that the current had the most significant influence on the multiple responses, followed by the welding speed.