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<p>Aluminum alloys are extensively utilized in structural components, automotive parts, maritime equipment, and general-purpose manufacturing. This study examines the mechanical properties, corrosion rate and structural changes in dissimilar weldments of aluminium alloys AA6082 and AA5083 using cold metal transfer (CMT) welding at different welding currents (230, 245, and 260&#xa0;A), speeds (300, 400, and 500&#xa0;rpm) and filament feed rates (6, 8, and 10&#xa0;mm/min). The study utilizes probability-based multi-objective optimization to systematically optimize the welding parameters and determine the ideal values that maximize tensile strength, hardness, and impact energy which was validated using analysis of variance (ANOVA). The designated welding parameters, including a current of 245&#xa0;A, a speed of 400&#xa0;mm/min, and a filament feed rate of 10&#xa0;mm/min, are found to be the optimal combination of welding parameters, balancing strength and ductility. The ultimate tensile strength for the optimal welded sample is found to be 202&#xa0;MPa. The ANOVA results highlighted that the filament feed rate had the most significant influence on the mechanical properties that contribute 85.67% to the variation which is followed by welding speed (8.37%) and current (5.96%). The optimal conditions enhanced mechanical properties and corrosion resistance through fine grain structures and reduced segregation. The corrosion test&#xa0;indicated remarkable resistance, with a corrosion rate of 0.004472&#xa0;mm/year, demonstrating the effectiveness of the optimized&#xa0;CMT welding parameters in improving the electrochemical stability and endurance of the weldments in corrosive environments.</p> Graphical Abstract <p></p>

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Mechanical and corrosion analyses of dissimilar weldments of AA6082 and AA5083 using CMT welding: a probability-based multi-objective optimization approach

  • 期刊论文

  • 发表日期：

    2025年7月28日

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  • E. C. Prasad Nidumolu,
  • Raj Kumar Pittala,
  • Balram Yelamasetti

摘要

Aluminum alloys are extensively utilized in structural components, automotive parts, maritime equipment, and general-purpose manufacturing. This study examines the mechanical properties, corrosion rate and structural changes in dissimilar weldments of aluminium alloys AA6082 and AA5083 using cold metal transfer (CMT) welding at different welding currents (230, 245, and 260 A), speeds (300, 400, and 500 rpm) and filament feed rates (6, 8, and 10 mm/min). The study utilizes probability-based multi-objective optimization to systematically optimize the welding parameters and determine the ideal values that maximize tensile strength, hardness, and impact energy which was validated using analysis of variance (ANOVA). The designated welding parameters, including a current of 245 A, a speed of 400 mm/min, and a filament feed rate of 10 mm/min, are found to be the optimal combination of welding parameters, balancing strength and ductility. The ultimate tensile strength for the optimal welded sample is found to be 202 MPa. The ANOVA results highlighted that the filament feed rate had the most significant influence on the mechanical properties that contribute 85.67% to the variation which is followed by welding speed (8.37%) and current (5.96%). The optimal conditions enhanced mechanical properties and corrosion resistance through fine grain structures and reduced segregation. The corrosion test indicated remarkable resistance, with a corrosion rate of 0.004472 mm/year, demonstrating the effectiveness of the optimized CMT welding parameters in improving the electrochemical stability and endurance of the weldments in corrosive environments.

Graphical Abstract