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<p>This study investigates the impact of different current waveforms on double-pulse metal inert gas (DP-MIG) welded joint and compares the results with conventional direct current pulse MIG welding. Emphasis is placed on evaluating their influence on the weld formation, porosity, microstructure, and mechanical properties of 6082 aluminum alloy joints. The presented experimental results indicate that the double-pulse welding process notably reduces the porosity, primarily owing to an augmented stirring effect. This effect is attributed to the synergistic influence of alternating arc forces, which stem from periodic variations in the current intensity and the corresponding fluctuations in droplet sizes within the molten pool. Furthermore, the DP-MIG welding process facilitates grain refinement in the weld region, yielding an average grain size of approximately 173.43 μm, thereby improving the overall mechanical properties of the joints. Owing to its lower heat input and efficient thermal cycling, the double-pulse welding method yields a narrower heat-affected zone (HAZ) and reduces grain coarsening, consequently enhancing overall weld quality. The fundamental mechanisms by which welding parameters govern joint quality are analyzed. A quantitative relationship is established linking welding parameters, microstructures, and mechanical properties. These findings offer practical insights into parameter optimization to maximize weld integrity and performance.</p>

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Effect of Current Waveform Characteristics on the Double-Pulse Metal lnert Gas Welded Joint for 6082 Aluminum Alloy

  • 期刊论文

  • 发表日期：

    2025年6月10日

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  • Weihan Wang,
  • Xiaopeng Gu,
  • Jiaxu Shao,
  • Xiaoyan Gu,
  • Lijuan Zhu

摘要

This study investigates the impact of different current waveforms on double-pulse metal inert gas (DP-MIG) welded joint and compares the results with conventional direct current pulse MIG welding. Emphasis is placed on evaluating their influence on the weld formation, porosity, microstructure, and mechanical properties of 6082 aluminum alloy joints. The presented experimental results indicate that the double-pulse welding process notably reduces the porosity, primarily owing to an augmented stirring effect. This effect is attributed to the synergistic influence of alternating arc forces, which stem from periodic variations in the current intensity and the corresponding fluctuations in droplet sizes within the molten pool. Furthermore, the DP-MIG welding process facilitates grain refinement in the weld region, yielding an average grain size of approximately 173.43 μm, thereby improving the overall mechanical properties of the joints. Owing to its lower heat input and efficient thermal cycling, the double-pulse welding method yields a narrower heat-affected zone (HAZ) and reduces grain coarsening, consequently enhancing overall weld quality. The fundamental mechanisms by which welding parameters govern joint quality are analyzed. A quantitative relationship is established linking welding parameters, microstructures, and mechanical properties. These findings offer practical insights into parameter optimization to maximize weld integrity and performance.