Metal Inert Gas (MIG) Welding Process Optimization for Joining Aluminum 5754 Sheet Material Using OTC/Daihen Equipment

Abstract

The development of lightweight vehicles, in particular aluminum intensive vehicles, require significant manufacturing process development for joining and assembling aluminum structures. Currently, 5xxx and 6xxx aluminum alloys are being used in various structural applications in a number of lightweight vehicles worldwide. Various joining methods, such as MIG, Laser and adhesive bonding have been investigated as technology enables for high volume joining of 5xxx, and 6xxx series alloys. In this study, metal inert gas (MIG) welding is used to join 5754 non-heat-treatable alloy sheet products. The objective of this study is to develop optimum weld process parameters for non-heat-treatable 5754 aluminum alloys. The MIG welding equipment used in this study is an OTC/Daihen CPD-350 welding systems and DR-4000 pulse power supply. The factors selected to understand the influence of weld process parameters on the mechanical properties and metallurgy (weld penetration) include power input (torch speed, voltage, current, wire feed), pulse frequency, and gas flow rate. Test coupons used in this study were based on a single lap configuration. A full factorial design of experiment (DOE) was conducted to understand the main and interaction effects on joint failure and weld penetration. The joint strengths and weld penetrations are measured for various operating ranges of weld factors. Post weld analysis indicates, power input and gas flow rate are the two signficant factors (statistically) based on lap shear load to failure and weld penentration data. There were no 2-way or 3-way interaction effects observed in ths weld study. Based on the joint strength and weld penetration, optimum weld process factors were determined.

Optimization of different welding processes using statistical and numerical approaches – A reference guide

“…Koganti et al [50] have employed a full factorial design to define the optimum weld MIG process parameters for non-treatable 5754 aluminium alloys. The effects of weld process parameters on the lap joint failure load (tensile-shear strength) and weld penetration were investigated.…”

Minimization of bead geometry by optimization of regression equations for laser-beam bead-on-plate welded Hastelloy C-276 sheet

“…Regression models were developed using the data obtained through experiment to predict suitable weld bead dimensions. Koganti et al [31] carried out a full factorial experiment to study the main effects as well as interaction effects of pulse frequency, power input and gas flow rate on weld strength and weld penetration for metal inert gas welding of 3.2-mm-thick Al5754 sheet. Prasad et al [32] carried out full factorial design for the development of regression model in order to correlate peak current, background current, pulse frequency and pulse width with weld bead dimensions for pulsed-current micro-plasma arc welding of 0.25-mm-thick SS304L sheets.…”

Experimental design approach to the process parameter optimization for laser welding of martensitic stainless steels in a constrained overlap configuration

“…It was concluded that these materials indeed possessed good laser weldability. Koganti et al [7] also applied a full factorial design to determine the optimum weld MIG process parameters for non-treatable 5754 aluminum alloys. The effects of weld process parameters on the lap joint failure load (tensileshearing strength) and weld penetration were investigated.…”