Effect of Double Pulse MIG Welding on Porosity Formation on Aluminium 5083 Fillet Joint

In this article, parameters of Double-Pulse Metal Inert Gas Welding (DP-MIG) was used for minimising a porosity formation in a T-joint fillet weld. AA5083-H112 aluminium alloy (Non-heat treatable series) with the plate thickness of 10 millimetres is base metal for this study. Welding consumables were filler wire ER5356 with a diameter of 1.2 millimetres and shielded by industrial argon gas. Three majorities parameter of DP-MIG were Delta wire feed (m/min), Frequency (Hz) and Duty cycle (%). Measurable signal current pattern and opened porosity on the fractured surface were couple observed to study their relationships. An appropriate image processing technique was employed to quantitative measuring and calculating a size grouping area of several opened porosities overall weld length, precisely. The result found that the optimal was used a low-level of Delta wire feed of 0.8 m/min, a high-level of a frequency of 5.0 Hz, a mid-level of the duty cycle 30 % and a high travel speed 60 cm/min could minimise the porosity formation with complete penetration.