Effect of thermal processes and welding related variables on mechanical properties of welded joints between 3003 and 6061 quality aluminum alloys

Date

2025-9-01

Author

Cengiz, Berkay

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In this study, 3003 H14 aluminum alloys and 6061 T6 aluminum alloys, mostly used in aerospace industry, were joined by Gas Tungsten Arc Welding (GTAW-TIG). Both are inspiring alloys that can be used together in aerospace applications for aircraft heat exchangers. The motivation of this study was to figure out finding the best welding scenario of dissimilar aluminum alloys joints that simultaneously obtain better mechanical performance and microstructural properties, thereby enabling repeatable, consistent heat exchangers. To determine variation interactions, an experimental matrix with 12 different scenarios was used. In addition to optical/BSE-SEM microstructure, SEM-EDS, XRD, SEM fractography, image analysis, a burst-pressure assessment of the welded product, study was complemented by transverse tensile, notched tensile, Charpy impact, hardness, and bend tests. Results showed that a proper cleaning, pulse mode presence alongside pre-heat application consistently yields the best results in the means of mechanical characterization test across other scenarios linked with microstructural and morphological outcomes. Also, favorable balance of α-Al phase dominance over Al–Si eutectic phase correlated with enhanced strength and ductility which is proved with SEM-EDS results and microstructural observations.

Subject Keywords

Aluminum welding, Mechanical properties, Microstructural evaluation, GTAW, 3003 and 6061 aluminum alloy

URI

https://hdl.handle.net/11511/116089

Collections

Graduate School of Natural and Applied Sciences, Thesis