FEA of GTAW process parameters for dissimilar materials of aluminium alloys

Abstract

The precision and adaptability of Gas Tungsten Arc Welding (GTAW), a popular welding technique, are well-known when it comes to combining disparate materials, especially aluminum alloys. In these kinds of applications, quality and integrity of welded joints are contingent upon the optimization of process parameters. With the help of Finite Element Analysis (FEA), engineers may effectively simulate and optimize welding operations by predicting the impact of various parameters on the quality of the weld. In order to better understand the welding process and produce higher-quality welds, this study focuses on the FEA of GTAW process parameters for various materials of aluminum alloys. Using FEA simulations, the primary goal of this research is to examine the impact of GTAW process parameters on the quality of welded joints between dissimilar aluminum alloys. The experimental setup entails the production of specimens made of aluminum alloy, followed by regulated GTAW welding. To verify FEA predictions, welding experiments record real-time data of process parameters and weld quality. Utilizing commercial software programs, the FEA simulations are carried out with material parameters, boundary conditions, and heat source models unique to GTAW processes for aluminum alloys. To evaluate the precision and dependability of the models, experimental data and the outcomes of FEA simulations are compared. The results shed light on the best way to combine process variables to get high-quality welds in different aluminum alloys. The study also looks into how process improvement may reduce errors and enhance the mechanical qualities of welded joints. All things considered, this work advances GTAW process parameter optimization for dissimilar material welding and provides engineers and researchers in the manufacturing, aerospace, and automotive industries with useful assistance. This study's findings may contribute to more dependable and effective welding procedures, which in turn may improve the performance and robustness of welded components in a range of applications.