Influence of Arc Ultrasonic on the Pore and Homogeneity of Microstructure in the Narrow Gap GMAW of Aluminum Alloy

doi:10.3901/JME.2025.20.134

Abstract

Abstract: Porosity defect and unhomogeneity of weld microstructure are the main causes of the decreased mechanical properties of narrow gap GMAW welded joint of thick wall aluminum alloy. In this paper, in order to reduce the porosity defect and improve the homogeneity of the microstructure in the weld, ultrasonic is introduced into the weld pool of 5083 aluminum alloy by parallel connection of ultrasonic power supply with the swing arc narrow gap GMAW system through capacitance and resistance. The effects of arc ultrasound on porosity and microstructure homogeneity of weld were investigated. The results show that：The introduction of arc ultrasonic in the narrow gap welding of aluminum alloy is beneficial to improve the homogeneity of pore distribution, reduce the number and size of pore, and then reduce the porosity of weld. After the application of arc ultrasound, the maximum porosity reduction of single-layer welding and multi-layer is 60.8% and 33.9%, respectively. After the application of arc ultrasound, the columnar crystal region decreases, the grain size from different parts of the weld decreases. The variances of grain diameter under non-arc ultrasound and applied arc ultrasound are 2.17×10³ and 1.48×10³, respectively. The microstructure homogeneity has been significantly improved for the swing arc narrow gap multilayer welding of 5083 aluminum alloy.

Key words: arc ultrasound, aluminium alloy, narrow gap welding, pore, homogeneity of microstructure

CLC Number:

TG444

CHEN Qihao, YING Yuefeng, XIE Zhiyu, LIN Sanbao, MAO Xinyu, WANG Jiayou. Influence of Arc Ultrasonic on the Pore and Homogeneity of Microstructure in the Narrow Gap GMAW of Aluminum Alloy[J]. Journal of Mechanical Engineering, 2025, 61(20): 134-142.

References

[1] 齐忠原，巫瑞智，王国军，等. 铝合金在船舶和海洋工程中的应用[J]. 轻合金加工技术，2016，44(1)：12-17. QI Zhongyuan，WU Ruizhi，WANG Guojun，et al. Application of aluminum alloys in shipping and ocean engineering[J]. Light Alloy Fabrication Technology，2016，44(1)：12-17.
[2] CUI H C，JIANG Z D，TANG X H，et al. Research on narrow-gap GMAW with swing arc system in horizontal position[J]. International Journal of Advanced Manufacturing Technology，2014，74(1-4)：297-305.
[3] ZHU J，WANG J Y，SU N，et al. An infrared visual sensing detection approach for swing arc narrow gap weld deviation[J]. Journal of Materials Processing Technology，2017，243(5)：258-268.
[4] 韩伟，李飞，王冲，等. 摇动电弧窄间隙立向上MAG焊接技术[J]. 机械工程师，2018(11)：138-141. HAN Wei，LI Fei，WANG Chong，et al. Technology of vertical-up swing arc narrow gap MAG welding[J]. Mechanical Engineer，2018(11)：138-141.
[5] ZHU C X，CHEON J，TANG X H，et al. Molten pool behaviors and their influences on welding defects in narrow gap GMAW of 5083 Al-alloy[J]. International Journal of Heat and Mass Transfer，2018，126：1206-1221.
[6] 陈琪昊，杨帆，朱杰，等. 厚壁铝合金摇动电弧窄间隙GMAW焊缝气孔分布与成形[J]. 江苏科技大学学报(自然科学版)，2021，35(2)：24-29. CHEN Qihao，YANG Fan，ZHU Jie，et al. Pore distribution and formation in swing arc narrow gap GMAW weld of thick-walled aluminum alloy[J]. Journal of Jiangsu University of Science and Technology (Natural Science Edition)，2021，35(2)：24-29.
[7] XU G X，WANG J Y，LI P F，et al. Numerical analysis of heat transfer and fluid flow inswing arc narrow gap GMA welding[J]. Journal of Materials Processing Technology，2018，252(5)：260-269.
[8] 胥国祥，潘海潮，王加友. 摇动电弧窄间隙GMAW焊温度场数值分析模型[J]. 焊接学报，2017，38(10)：55-60. XU Guoxiang，PAN Haichao，WANG Jiayou. Numerical analysis model of temperature field in swing-arc narrow gap GMAW[J]. Transactions of the China Welding Institution，2017，38(10)：55-60.
[9] TRAIDIA A，ROGER F，SCHROEDER J，et al. On the effects of gravity and sulfur content on the weld shape in horizontal narrow gap GTAW of stainless steels[J]. Journal of Materials Processing Technology，2013，213(7)：1128-1138.
[10] XU W H，LIN S B，FAN C L，et al. Statistical modelling of weld bead geometry in oscillating arc narrow gap all-position GMA welding[J]. International Journal of Advanced Manufacturing Technology，2014，72(9-12)：1705-1716.
[11] XU W H，LIN S B，FAN C L，et al. Prediction and optimization of weld bead geometry in oscillating arc narrow gap all-position GMA welding[J]. International Journal of Advanced Manufacturing Technology，2015，79(1-4)：183-196.
[12] BAO Y，XUE R L，ZHOU J P，et al. Effect of increasing oscillation width on the arc characteristics and droplet transfer behavior of X80 steel in the overhead welding position of narrow gap P-GMAW[J]. Metals，2023，13(7)：1314.
[13] LIU H S，XUE R L，ZHOU J P，et al. Applying statistical models to optimize the weld bead geometry in the vertical oscillation arc narrow gap all-position GMAW[J]. Applied Sciences-Basel，2023，13(11)：6801.
[14] BAO Y，XUE R L，ZHOU J P，et al. The influence of oscillation parameters on the formation of overhead welding seams in the narrow-gap GMAW process[J]. Applied Sciences-Basel，2023，13(9)：5519.
[15] 吴来军，刘一搏，王亚峰，等. 摆动电弧对铝合金厚板窄间隙焊侧壁熔深的影响[J]. 热加工工艺，2017，46(13)：72-75. WU Laijun，LIU Yibo，WANG Yafeng，et al. Effects of oscillating arc on sidewall penetration of aluminum alloy thick plate welding[J]. Hot Working Technology，2017，46(13)：72-75.
[16] 闫久春，杨春利，刘会杰，等. 超声复合焊接研究现状及科学问题[J]. 机械工程学报，2015，51(24)：41-47. YAN Jiuchun，YANG Chunli，LIU Huijie，et al. Overview on ultrasonic-assisted welding and its scientific issues[J]. Journal of Mechanical Engineering，2015，51(24)：41-47.
[17] YE M C，WANG Z Y，BUTT H A，et al. Enhancing the joint of dissimilar aluminum alloys through MIG welding approach assisted by ultrasonic frequency pulse[J]. Materials Letters，2023，330：133289.
[18] WANG D Q，HUA C，LU H. Numerical analysis of ultrasonic waves in the gas tungsten arc welding (GTAW) with ultrasonic excitation of current[J]. International Journal of Heat and Mass Transfer，2020，158：119847.
[19] 从宝强，齐铂金，周兴国，等. 铝合金超快变换复合脉冲方波VPTIG焊接技术[J]. 焊接学报，2009，30(2)：25-28. CONG Baoqiang，QI Bojin，ZHOU Xingguo，et al. Ultrafast convert complex ultrasonic pulse square wave VPTIG arc welding technology of aluminum alloy[J]. Transactions of the China Welding Institution，2009，30(2)：25-28.
[20] 刘刚，杜佳，王岩，等. 超声电弧对304不锈钢TIG水下焊接组织及力学性能的影响[J]. 焊接技术，2023，52(12)：54-58. LIU Gang，DU Jia，WANG Yan，et al. Effect of arc-ultrasonic on microstructure and mechanical properties of 304 stainless steel with underwater TIG welding[J]. Welding Technology，2023，52(12)：54-58.
[21] WANG Y P，LI H，LI Z X，et al. Refining microstructure of medium-thick AA2219 aluminium alloy welded joint by ultrasonic frequency double-pulsed arc[J]. Journal of Materials Research and Technology，2023，23：3048-3061.
[22] KOMAROV S，ODA K，ISHIWATA Y，et al. Characterization of acoustic cavitation in water and molten aluminum alloy[J]. Ultrasonics Sonochemistry，2013,20(2)：754-761.
[23] TZANAKIS I，LEBON G S B，ESKIN D G，et al. Characterisation of the ultrasonic acoustic spectrum and pressure field in aluminium melt with an advanced cavitometer[J]. Journal of Materials Processing Technology，2016，229：582-586.
[24] 徐海鹏，路林，贾征，等. 超声处理对Al-2Sn合金凝固组织及除气效果的影响[J]. 热加工工艺，2024，53(15)：19-21，26. XU Haipeng，LU Lin，JIA Zheng，et al. Effect of ultrasonic treatment on solidification microstructure and degassing effect of Al-2Sn alloy[J]. Hot Working Technology，2024，53(15)：19-21，26.
[25] LIU J，ZHU H Y，LI Z，et al. Effect of ultrasonic power on porosity，microstructure，mechanical properties of the aluminum alloy joint by ultrasonic assisted laser-MIG hybrid welding [J]. Optics and Laser Technology，2019，119：105619.
[26] CHEN Q H，XIE Z Y，WANG J Y，et al. A comparison of the swing and non-swing arc behavior in arc ultrasonic assisted narrow gap GMAW[J]. Journal of Materials Research and Technology，2023，24：4698-4710.
[27] CAI X Y，LIN S B，WANG X N，et al. Characteristics of periodic ultrasonic assisted TIG welding for 2219 aluminum alloys[J]. Materials，2019，12(24)：1-11.
[28] LAN H X，GONG X F，ZHANG S F，et al. Ultrasonic vibration assisted tungsten inert gas welding of dissimilar metals 316L and L415[J]. International Journal of Minerals Metallurgy and Materials，2020，27(7)：943-953.