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In this study, the effect of variation of intermittent wire feeding method on thermal histories during the welding process, the physical appearance, mechanical properties, and fracture mode was investigated. The configuration parameter of wire feeding was determined by the properties of the so-called length ratio (RL). It was influenced by welding speed, wire feeding speed, feeding time, and delaying time. Bigger value of length ratio tends to have a smaller bead width with a higher cap. Also, a larger ratio tends to have bigger tensile strength and the fracture location close to the weld bead.

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In this present study, the two independent tools were used in the RFSSW process to joint similar material of AA1100 with a thickness of 0.42 mm using lap joint configuration. Effect of tools geometry and dwell time on mechanical properties, and macrograph was investigated. The joints were successfully obtained with better surface appearance. The micro-hardness variation at 4 group location shows higher than the base metal, while the maximum micro-hardness was obtained at parameter TC-8 at the center of the weld. Macrograph analysis showed the important factor that brings the plug fracture in all combination of parameters. It was the upward bending hook that leads to the crack propagate along the stirred zone to the top sheet, resulted in tear-off the top sheet from the bounded region. Increasing dwell time and tools size will increase the maximum tensile shear load significantly. The best average value of maximum tensile shear load that has been achieved was 561±24 N using the parameter tool C with 8 s dwell time (TC-8).

In this paper, an autogenous tungsten inert gas (TIG) welding was performed to understand the characteristic effect of butt joint weld on AA1100 under various parameters. The effect of TIG current and welding speed was selected to study the mechanical properties, porosity, and macrostructure of the weld metal (WM). Based on experimental results, the top bead width (TBW) will increase directly proportional to the increased of welding current. Furthermore, welding current and welding speed affected the strength drop in the heat-affected zone (HAZ). More heat added will result in a deeper drop in strength. Mechanical properties result showed that the tensile strength reduced by 40 – 45% and the hardness reduction in the WM and HAZ area from the base metal (BM) was 17.3% and 27.7%, respectively. Subsequently, X-Ray radiography images showed that there was no large porosity occur in all welding current. The macrostructure showed that the weld bead typically has the concavity shape or U-shaped geometry from a cross-sectional view.