| Abstract Scope |
Aluminum alloys 6082 and 6005 are commonly used in automotive battery enclosures due to their strength and corrosion resistance. However, arc welding these alloys often leads to hot cracking and oxide layer formation, compromising weld quality. Cold Metal Transfer (CMT), a proprietary low heat input MIG welding process developed by Fronius International GmbH, addresses these issues by reducing spatter, porosity, and strength loss. This study focuses on optimizing welding parameters to minimize heat input and defects while enhancing weld performance. Using a Design of Experiments (DoE) approach, both alloys were welded and key performance indicators—Weld Aspect Ratio, Hardness, and Tensile Strength—were evaluated, alongside microstructural analysis to examine grain refinement and fusion zone characteristics. The findings reveal how welding parameters influence microstructure and mechanical properties, offering valuable insights for improving weld quality in aluminum alloy battery enclosures. |