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<p>This study aims to comparatively evaluate the comprehensive performance of dissimilar aluminum alloy joints (2024-T3 and 5083) and identify the optimal filler wire by systematically investigating the effects of three distinct filler wires (BJ-380D, ER5B06 and ER2325) during TIG welding. The microstructure, mechanical properties and corrosion resistance of the resulting dissimilar welded joints were systematically investigated. The results reveal Cu segregation at the WZ grain boundaries in all three joints, with ER5B06 exhibiting particularly pronounced macroscopic segregation. This Cu segregation promotes the formation of coarse θ and S phases within the WZ, resulting in varying degrees of softening across all joints. The ER5B06 joint show more significant softening, primarily due to significant magnesium evaporation and burn-off caused by the high heat input during welding, which diminishes solid solution strengthening effect. Notably, the hardness of the 2024-HAZ exhibits a regular fluctuation pattern, enabling its division into four characteristic zones. TEM characterization confirms that these hardness variations correlate closely with the evolution of the precipitates. Tensile test results show that the tensile strength of all three welded joints reaches approximately 93% of that of the base material. Corrosion performance studies demonstrate that ER5B06-WZ exhibits the poorest corrosion resistance due to macroscopic segregation. In the ER2325-WZ, the intermetallic compounds are uniformly and continuously distributed, which fails to effectively block corrosion pathways, resulting in higher IGC sensitivity compared to the BJ-380D-WZ, where the compounds exhibit a discontinuously distribution. The higher heat input (262.5&#xa0;J/mm) used for ER5B06 leads to the formation of a wider PFZ in the 2024-HAZ2 region, significantly increasing corrosion sensitivity and degrading corrosion resistance. The welded joints fabricated with the BJ-380D filler wire demonstrate the most balanced and superior comprehensive performance in terms of mechanical properties and corrosion resistance. This provides a reliable technical reference for TIG welding of dissimilar 2024-T3/5083 aluminum alloys.</p>

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Effect of filler wire composition on microstructure evolution and properties in TIG-welded dissimilar 2024–5083 aluminum alloy joints

  • 期刊论文

  • 发表日期：

    2026年4月8日

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  • Caimei Wang,
  • Yifeng Zhang,
  • Yuancheng Fan,
  • Weiming Huang,
  • Yuxin Wu,
  • Shangpu Zhou,
  • Peiyi Li,
  • Yuanyuan Zang,
  • Feng Han,
  • Yu Zhang

摘要

This study aims to comparatively evaluate the comprehensive performance of dissimilar aluminum alloy joints (2024-T3 and 5083) and identify the optimal filler wire by systematically investigating the effects of three distinct filler wires (BJ-380D, ER5B06 and ER2325) during TIG welding. The microstructure, mechanical properties and corrosion resistance of the resulting dissimilar welded joints were systematically investigated. The results reveal Cu segregation at the WZ grain boundaries in all three joints, with ER5B06 exhibiting particularly pronounced macroscopic segregation. This Cu segregation promotes the formation of coarse θ and S phases within the WZ, resulting in varying degrees of softening across all joints. The ER5B06 joint show more significant softening, primarily due to significant magnesium evaporation and burn-off caused by the high heat input during welding, which diminishes solid solution strengthening effect. Notably, the hardness of the 2024-HAZ exhibits a regular fluctuation pattern, enabling its division into four characteristic zones. TEM characterization confirms that these hardness variations correlate closely with the evolution of the precipitates. Tensile test results show that the tensile strength of all three welded joints reaches approximately 93% of that of the base material. Corrosion performance studies demonstrate that ER5B06-WZ exhibits the poorest corrosion resistance due to macroscopic segregation. In the ER2325-WZ, the intermetallic compounds are uniformly and continuously distributed, which fails to effectively block corrosion pathways, resulting in higher IGC sensitivity compared to the BJ-380D-WZ, where the compounds exhibit a discontinuously distribution. The higher heat input (262.5 J/mm) used for ER5B06 leads to the formation of a wider PFZ in the 2024-HAZ2 region, significantly increasing corrosion sensitivity and degrading corrosion resistance. The welded joints fabricated with the BJ-380D filler wire demonstrate the most balanced and superior comprehensive performance in terms of mechanical properties and corrosion resistance. This provides a reliable technical reference for TIG welding of dissimilar 2024-T3/5083 aluminum alloys.