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<p>The high-strength aluminum alloy AA-7075-T6 is widely used in the aerospace, military, and automotive industries due to its excellent strength-to-weight ratio. However, fusion welding of this alloy poses major challenges, such as a high susceptibility to hot cracking, the formation of secondary phases, and porosity factors that significantly limit its broader application. This study explores the use of mechanically induced vibration during the Gas Metal Arc Welding (GMAW) process, employing the Surface Tension Transfer (STT®) module. The investigation focused on how welding parameters and vibration frequency affect porosity, microstructure, and the hardness of the welded joints. The results showed that applying vibration significantly reduced porosity, refined the secondary phases η (MgZn₂) and Mg(Zn,Cu,Al), absence of cracking, and decreased the width of the heat-affected zone (HAZ).The novelty of this research lies in combining mechanical vibration with the STT® process, an approach rarely explored for welding high-strength alloys like AA-7075-T6. These findings demonstrate that the technique is a promising alternative to enhance the metallurgical integrity and mechanical performance of welded joints, expanding the potential applications of this alloy in demanding structural environments.</p>

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Influence of the applied mechanical vibration on the porosity level, microstructure and hardness of the AA-7075-T6 alloy weldments using GMAW-STT process

  • 期刊论文

  • 发表日期：

    2025年7月21日

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  • Diogo Aranha Ribeiro,
  • Carlos Alberto Carvalho Castro,
  • Eduardo Pereira da Silva,
  • Edmilson Otoni Correa

摘要

The high-strength aluminum alloy AA-7075-T6 is widely used in the aerospace, military, and automotive industries due to its excellent strength-to-weight ratio. However, fusion welding of this alloy poses major challenges, such as a high susceptibility to hot cracking, the formation of secondary phases, and porosity factors that significantly limit its broader application. This study explores the use of mechanically induced vibration during the Gas Metal Arc Welding (GMAW) process, employing the Surface Tension Transfer (STT®) module. The investigation focused on how welding parameters and vibration frequency affect porosity, microstructure, and the hardness of the welded joints. The results showed that applying vibration significantly reduced porosity, refined the secondary phases η (MgZn₂) and Mg(Zn,Cu,Al), absence of cracking, and decreased the width of the heat-affected zone (HAZ).The novelty of this research lies in combining mechanical vibration with the STT® process, an approach rarely explored for welding high-strength alloys like AA-7075-T6. These findings demonstrate that the technique is a promising alternative to enhance the metallurgical integrity and mechanical performance of welded joints, expanding the potential applications of this alloy in demanding structural environments.