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Article

TIG Welding of EN AW-6082 Al Alloy: A Comparative Analysis of Filler Rods on Microstructural and Mechanical Performance

by
Bandar Alzahrani
1,
Mohamed M. Z. Ahmed
1,*,
Mohamed I. A. Habba
2,
Ramy A. Fouad
2,
Yousef G. Y. Elshaghoul
3 and
Elshafey Ahmed Gadallah
2
1
Mechanical Engineering Department, College of Engineering at Al-Kharj, Prince Sattam Bin Abdulaziz University, Al-Kharj 16273, Saudi Arabia
2
Mechanical Department, Faculty of Technology and Education, Suez University, Suez 43221, Egypt
3
Mechanical Engineering Department, Faculty of Engineering, Suez University, Suez 43221, Egypt
*
Author to whom correspondence should be addressed.
J. Manuf. Mater. Process. 2025, 9(1), 21; https://doi.org/10.3390/jmmp9010021
Submission received: 16 December 2024 / Revised: 5 January 2025 / Accepted: 10 January 2025 / Published: 13 January 2025
(This article belongs to the Special Issue Advances in Welding Technology)
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Abstract

This study investigates the impact of different filler wires (ER5356, ER4043, and ER4047) on the microstructural and mechanical properties of EN AW-6082 Al alloy joints produced by tungsten inert gas (TIG) welding. Butt-welded samples with a single V-groove joint configuration were prepared using optimized welding parameters. The welded samples were subjected to visual inspection, microstructural analysis, hardness testing, tensile testing, and impact toughness evaluation. The results showed that all the welds were free of visible defects. Microstructural examination revealed that the ER5356 filler produced the finest grain structure of 18.03 ± 3 μm, while ER4047 resulted in the coarsest grains of 36.07 ± 5 μm. Correspondingly, the joints made with ER5356 exhibited the highest tensile stress of 278 ± 6 MPa, yield stress of 219 ± 5.4 MPa, hardness values of 72.7 ± 5 HV, and welding efficiency of 86.07%, whereas those made with ER4047 produced the lowest values. The hardness in the weld region was lower than that in the parent metal and heat-affected zone for all samples. However, ER4047 welds demonstrated superior impact toughness and strain-hardening capacity. The findings underscore the importance of filler metal selection in tailoring mechanical properties for high-performance applications.
Keywords: filling wire; EN AW-6082 alloy; TIG process; microstructure; mechanical behavior filling wire; EN AW-6082 alloy; TIG process; microstructure; mechanical behavior

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MDPI and ACS Style

Alzahrani, B.; Ahmed, M.M.Z.; Habba, M.I.A.; Fouad, R.A.; Elshaghoul, Y.G.Y.; Gadallah, E.A. TIG Welding of EN AW-6082 Al Alloy: A Comparative Analysis of Filler Rods on Microstructural and Mechanical Performance. J. Manuf. Mater. Process. 2025, 9, 21. https://doi.org/10.3390/jmmp9010021

AMA Style

Alzahrani B, Ahmed MMZ, Habba MIA, Fouad RA, Elshaghoul YGY, Gadallah EA. TIG Welding of EN AW-6082 Al Alloy: A Comparative Analysis of Filler Rods on Microstructural and Mechanical Performance. Journal of Manufacturing and Materials Processing. 2025; 9(1):21. https://doi.org/10.3390/jmmp9010021

Chicago/Turabian Style

Alzahrani, Bandar, Mohamed M. Z. Ahmed, Mohamed I. A. Habba, Ramy A. Fouad, Yousef G. Y. Elshaghoul, and Elshafey Ahmed Gadallah. 2025. "TIG Welding of EN AW-6082 Al Alloy: A Comparative Analysis of Filler Rods on Microstructural and Mechanical Performance" Journal of Manufacturing and Materials Processing 9, no. 1: 21. https://doi.org/10.3390/jmmp9010021

APA Style

Alzahrani, B., Ahmed, M. M. Z., Habba, M. I. A., Fouad, R. A., Elshaghoul, Y. G. Y., & Gadallah, E. A. (2025). TIG Welding of EN AW-6082 Al Alloy: A Comparative Analysis of Filler Rods on Microstructural and Mechanical Performance. Journal of Manufacturing and Materials Processing, 9(1), 21. https://doi.org/10.3390/jmmp9010021

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