About this Abstract |
| Meeting |
MS&T25: Materials Science & Technology
|
| Symposium
|
Lightweight Composites, Materials & Alloys
|
| Presentation Title |
Investigating Filler Wire Contributions to Porosity and Strength in Al 6061-T6 Welds |
| Author(s) |
Tinku Kumar, Hariharan V S |
| On-Site Speaker (Planned) |
Tinku Kumar |
| Abstract Scope |
Porosity during welding of aluminum alloys is critical as it affects the mechanical properties and functionality of the part. In the present study, commonly used filler wires of aluminum-silicon alloys ER4043 and ER4047 in two diameters of 1.2 mm and 1.6 mm were studied in the purview of porosity, distortion and mechanical properties in the welding of 6061-T6 alloy. A semi-analytical model was used to understand the impact of filler wire and process parameters on the porosity evolution. The model predictions matched qualitatively with the experimental observations and trends. The study found that using ER4047 wire of 1.6 mm thickness with Precision PulseŽ waveform produces industry-standard weld quality with almost zero porosity, superior mechanical properties, and negligible distortion levels while improving the productivity for thicknesses up to 3 mm. This information is crucial for the automotive industry as it seeks to increase the use of Lightweight aluminum in vehicles. |