International Journal of Advanced Engineering Technology E-ISSN 0976-3945

Research Article
EXPERIMENTAL INVESTIGATIONS ON PULSED TIG
WELDING OF ALUMINIUM PLATE
Sanjeev Kumar

Address for correspondence

Lecturer, Beant College of Engg. & Technology Gurdaspur, INDIA

ABSTRACT
Aluminium Plates (3-5mm thickness) are being commercially welded by Pulsed Tungsten Inert Gas Welding
Process (PTIGW). In the present work, an attempt has been made to explore the possibility for welding of
higher thickness plates. An aluminium plate of 6mm thickness has been selected as specimen. Input process
parameters (Mean Welding Current, Pulsed Current, and Gas Flow Rate) were varied according to full
factorial experimental design. The output parameters were (Tensile Strength and Shear Strength).
Photomicrographs of welded Specimens were taken and analyzed. The results of the study will be useful for
enhancing commercial application of PTIGW on higher thickness aluminum plates. Also the study highlight
reasons for not using DC power source for welding of aluminum plates.

INTRODUCTION Al are GMAW, and GTAW. GTAW was the

Aluminium based alloys have been widely
used in automobile structures due to their
unique properties, such as high strength to
weight ratio. Although large-scale production
of aluminium intensive vehicles will not be
feasible in near future, there is no doubt that
the use of aluminium based material will
increasing steadily. Aluminium and its alloys
can be joined by most fusion and solid state
welding processes, as well as by brazing and
soldering. Fusion welding is commonly done
by GMAW, GTAW and resistance spot and
seam welding. Plasma and Electron Beam
Welding are used in special applications.
SMAW and oxy-fuel gas welding may be used
for applications where high strength and
quality are not essential for the intended
service. Two welding process mostly used for
first arc welding process applied to aluminum.
It produces very attractive welds, with good
profile, edge wetting and bright appearance.
GTAW welding, often requiring hand fed filler
rod to build up the weld deposit. In GTAW
welding technique the tungsten electrode is
used to strike arc and melt the base metal where
welding is to be done. Depending upon the
thickness of the weld joint, the filler wire is
added to the molten weld puddle.
PULSED TIG WELDING
This is modified version of TIG welding, in
which the welding current (DC) is fed
intermittently in the form of pulses. The pulsed
current alternates between a low or background
level and a peak level. The duration and
amplitude of both peak and background
currents can be varied independently to suit the

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job. The melting takes place during the peak During welding, gas flow rate was kept at
current period, and the weld pool solidifies 7 litre/min.
between pulses as the heat is dissipated in the Welding has been performed by variation
job during the background current period. This of five levels DC-Current (i.e.48, 64, 80,
current pulsing leads to intermittently melting 96, 112 Amp.)
along the joint seam, giving a series of CASE-II: Welding of specimen, performed by
discrete melt spots, which overlap each other. using AC-Current source:
Advantages of the Process are:
During welding; Pulse-Frequency (4 Hz)
It tolerates variation in the joint fit-up or
and Pulse-Width (60 s) have been kept
clamping.
constant.
It permits welding of sheets down to 1 mm
Gas flow rate has been used as 7 litre/min
with ease, which is normally difficult by
and 15 lire/min.
standard TIG process.
During Its phase, three levels of base
It minimizes distortions owing to
current i.e., 100A, 150A, and 200A; and
controlled heat input.
gas flow rate of 7litre/min have been used
It makes positional welding easy. for welding of specimen.
It requires less operator skill as compared Then at each value of mean current, the
to the normal TIG process. pulse current has been varied (i.e.100,150,
It shows marked improvement in weld 200, 250&300 Amp.) for welding.
quality. During 2nd phase, welding has been
It is suited to mechanization/automation. carried out by using three values of base
The strong electromagnetic forces current i.e., 100A, 150A and 200 A and
developed by the high pulse of current gas flow rate of 15 litre/min.
agitate the weld puddle and therefore Then at each value of mean current used,
eliminate weld porosity and thorough as mentioned above, the Pulse Current has
root fusion. been varied (i.e. 100A, 150A, 200A,
Welding of Plates: 250A and 300 A) to carry out the welding
CASE-I: Welding of specimen, performed by of specimen.
using DC-Current source:

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EXPERIMENTATION AND TESTING Gas flow rate : variable

Material: Pulsed frequency : constant
Shielding Gas: Commercially available argon Pulsed width : constant
99.97% was used as shielding gas. Output Parameters
Filler Material: Aluminum filler wire of 4.8
Ultimate tensile strength
mm diameter was used in this work for
Shear strength
disposition of weld metal.
Microstructure
Non-Consumable: Commercial available EXPERIMENTAL OBSERVATIONS:
Tungsten (99.75 %) is used as electrode The observations during
material. experimentation are given in table (1) to table
Base material: In the present investigation, (3). The observation for DC Welding are
extruded section (100mm x 50mm x 6mm) of given in table (1), where the minimum current
commercial Aluminium Alloys was used as is 48 Amp from which welding is started and
base material. The chemical composition of maximum is 112 Amp after that the weld
filler alloys is given below. piece is started burning. While during welding
by using Pulsating TIG, the welding is
performed at 7 litre/min and 15litre/min gas
WELDING PARAMETERS DURING flow rate by using five values of Pulsed
EXPERIMENTATION: current (i.e. 100, 150, 200, 250, and 300 Amp)
Input Parameters at three values of mean current (i.e. 100, 150
Welding Current : variable and 200Amp ), the observation is given in
Pulsed current : variable table( 2 ) and (3 ).
Table 1: Welding parameters during experimentation for DC-current source at
7 litre/min Flow rate.
Sr. No. Specimen Designation DC- Current(Amp)
1 A 48
2 B 64
3 C 80
4 D 96
5 E 112

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Table 2: Welding Parameters during experimentation for Pulsed Current Source at

Pulse Frequency (60 HZ), Pulse Width (4s) and Gas Flow Rate 7 litre /min.
Sr.No. Specimens Mean/Pulse Mean Welding Pulse
Designation Current Current (Amp) Current
(Amp)
1 A1 Mean 100 -

2 A2 Mean 150 -

3 A3 Mean 200 -

4 A4 Pulse &Mean 100 100

5 A5 Pulse & Mean 100 150

6 A6 Pulse & Mean 100 200

7 A7 Pulse &Mean 100 250

8 A8 Pulse & Mean 100 300

9 A9 Pulse & Mean 150 100

10 A10 Pulse & Mean 150 150

11 A11 Pulse &Mean 150 200

12 A12 Pulse & Mean 150 250

13 A13 Pulse & Mean 150 300

14 A14 Pulse & Mean 200 100

15 A15 Pulse & Mean 200 150

16 A16 Pulse & Mean 200 200

17 A17 Pulse & Mean 200 250

18 A18 Pulse & Mean 200 300

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Table 3: Welding Parameters during experimentation for Pulsed Current Source

at Pulse Frequency (60 HZ), Pulse Width (4s) and Gas Flow Rate 15litre /min.
Sr.No. Specimens Mean/Pulse Mean Welding Pulse Current
Designation Current Current (Amp) (Amp)
1 B1 Mean 100 -
2 B2 Mean 150 -
3 B3 Mean 200 -
4 B4 Pulse & Mean 100 100
5 B5 Pulse & Mean 100 150
6 B6 Pulse & Mean 100 200
7 B7 Pulse & Mean 100 250
8 B8 Pulse & Mean 100 300
9 B9 Pulse & Mean 150 100
10 B10 Pulse & Mean 150 150
11 B11 Pulse & Mean 150 200
12 B12 Pulse & Mean 150 250
13 B13 Pulse & Mean 150 300
14 B14 Pulse & Mean 200 100
15 B15 Pulse & Mean 200 150
16 B16 Pulse & Mean 200 200
17 B17 Pulse & Mean 200 250
18 B18 Pulse &Mean 200 300

TESTING OF SPECIMENS: Rough polishing.

Metallographic examination:
The specimens for metallographic study
were cut from the welded plate. The
procedural steps involved in the specimens
preparation were as follow: -
Selection of specimen.
Cutting of the specimen.
Obtaining the flat specimen.
Intermediate & fine grinding.
Fine Polishing & Fine Lapping.
Etching.
Taking Photographs of features of
interest.
The specimen were initially polished with various
grades of emery papers having grade 200, 300,
400, 600, 800 from coarse to fine respectively on
disc polishing machine. Then lapping with velvet
cloth by using polishing grade alumina powder on

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 International Journal of Advanced Engineering Technology
a disc polishing Machine was done. The
specimens now had smooth mirror like
surface finish without any scratches. The
polished specimens were etched by 2%
NITAL (98%methyl alcohol and 2% nitric
acid). The etched surface revealed the weld
metal and the HAZ. The microstructures
were studied under microscope and the
interesting features were photographed.
MECHANICAL TESTING:
Tensile Testing:
Two types of welded specimens were
produced by using:
DC at 48A, 64A, 80A, 96A & 112A,
keeping the gas flow rate constant at 7
litre/min.
Pulse Current Values are set as 100A,
150A, 200A, 250A & 300A at Mean
Current Values of 100A, 150A & 200A,
keeping the gas flow rates at 7 litre/min
and 15litre/min.
Flat transverse tensile test specimens were
cut, from such welded specimens, for the
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comparison of their Ultimate Tensile Strength.
Shear Testing:
Two types of welded specimens were produced by
using:
DC at 48A, 64A, 80A, 96A & 112A, keeping
the gas flow rate constant at 7 litre/min.
Pulse Current Values are set as 100A, 150A,
200A, 250A & 300A at Mean Current Values
of 100A, 150A & 200A, keeping the gas flow
rates at 7 litre/min and 15litre/min.
Flat transverse Shear test specimens were cut,
from such welded specimens, for the comparison
of their Shear Strength.
RESULTS AND DISCUSSION:-
Results with D.C. Current Source:
Experiment were conducted at different values of
D.C. current (48 ,64,80,96,and 112 Amps)
Keeping gas flow rate constant at 7litre/min.
Tensile and Shear strength was measured and
tabulated (4 & 5), with their variations with
current. Photomicrograph of welded specimens at
different values of DC current as shown in fig (1).
 International Journal of Advanced Engineering Technology E-ISSN 0976-3945

Results with Pulsed current Source:
Experiment were conducted at different values
of Pulsed current (100 ,150,200,250,and 300
Amps) at Mean Current (100,150 and 200)
Keeping gas flow rate constant at 7litre/min
and 15 litre/min. Tensile and Shear strength
was measured and tabulated (6 to 11),with
their variations with current. Photomicrograph
of welded specimens at different values of
Pulsed current as shown in fig (2 & 3).

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DISCUSSION happened due to accumulation of

significant amount of porosity in this
Discussion on tensile strength using DC-
region.
Current Source and fix gas flow rate
Discussion of shear strength using DC-
It has been observed that tensile testing of
Current Source and fix gas flow rate
weld joints, the tensile fracture has been
The shear strength of weld metal at direct
found to take place from the weld deposit
current and gas flow (7 litre/min) welding
close to the fusion line, this has primarily
strength approximately 73 MPa, which is

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very less than the shear strength of parent
metal having 85MPa due to lack of refined
grain structure of Weldments
Discussion on Microstructure using DC-
Current Source and fix flow rate of gas
The weld deposits are found to have co-axial
dendrite microstructure towards the fusion
line, but equiaxed grains at the central region
of weld deposit is attributed to segregation of
impurities of commercial, Aluminium
resulting in the formation of more nucleation
sites at this region.
During direct current welding the variation in
current effect the microstructure of these
regions. Microstructure of central region of
weld produced at different current of 48, 80,
and 112 Amps has shown fig. (1). This fig.
Shows the effect of current 48, 80, & 112
Amps respectively. Microstructure of the
weld deposit also shows the presence of
porosity in it, the amount of which
qualitatively found to vary with the current.
Discussion on Tensile strength using Pulse-
Current
In all cases of tensile testing of weld joints,
the tensile fracture has been found to take
place from the weld deposit close to fusion
fine, this has primarily happened due to
accumulation of Significant amount of
porosity in this region. In the order achieve a
good tensile strength of weld joint of pulse
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current weldments, it is very much
important to take care of right selection of
parameters which generally observed as the
pulse current of 250 Amp at 200 Amp mean
current and 15 litre/min gas flow rate.
Discussion on Shear strength using Pulse
current Welding
It has to been seen that in all shear strength
has been varies with the change of pulse
current and thus affecting the shear
strength. Lack of refined grain structure of
weldments gives poor strength. It has been
observed at pulse current 250Amp and gas
flow rate 15 litre/min and base current 200
Amp. Gives better results than overall. This
is due to refined grain structure, cause to
formation of proper bond.
Discussion on Microstructure using Pulse
Welding
The weld deposits are found to have co-
axial dendrite microstructure towards the
fusion line, but equiaxed grains at the
central region of weld deposit is attributed
to segregation of impurities of commercial
aluminium resulting in formation of more
nucleating sites at this region. During pulse
current welding, the variation in pulse
parameter effect the weld thermal cycle,
thus it may influence the microstructure of
these regions.
 International Journal of Advanced Engineering Technology
Microstructure of the weld deposit also
shows the presence of porosity in it, the
amount of which qualitatively found to vary
with the pulse parameters especially with the
variation of pulse current. This has happened
primarily due to fluctuation in presence with
the change in pulse current resulting in
creation of turbulence in the shielding jacket
of inert gas, which causes air aspiration in it.
Sometime it is also observed that significant
amount of porosity are along the weld
deposit close to fusion line.
CONCLUSIONS
On the basis of present experimental work
following conclusion were drawn
The welded joints have been found to
fracture from the weld deposit, close to
fusion line. This is because of presence
of porosity in this area. The porosity
content of this area has been found to
vary with the pulse parameters and gas
flow rate.
The tensile strength of pulse TIG welded
joint has been found to be comparable
with those with DC-Current, when
prepared at some gas flow rate i.e. 7 litre
/min. It is found that tensile strength is
optimum at pulse current of 250 Amp
and gas flow rate of 15 litre/min and base
current 200 Amp. s
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It has been observed that Shear Strength
varies with change of pulse current.
This change in Shear Strength is due to
lack of refined grain structure of
weldments, responsible for poor
strength.
Maximum value of Shear Strength has
been observed at pulse current of 250A,
gas flow rate of 15 litre /min and base
current 200 Amp.
Microstructure of weld deposited has
been found to have two distinct zones,
containing co-axial dendrites adjacent to
fusion line and the fine equiaxed grain,
in the region of weld center.
The microstructure, has been found to
be very refined grain structure at pulse
current 250A & gas flow rate of 15 litre
/min. at base current of 200 A.
SCOPE OF FUTURE WORK
The research work can be further taken up
on different sizes of aluminium plates as
per the application/ requirement of industry.
In the present work, only few process
parameters have been investigated, keeping
other parameters constant. Study of these
constant process parameters, like gas flow
rate, welding current can be done.
Further experimentation can be performed
to study possible interaction among
variables that affect the performance of the
 International Journal of Advanced Engineering Technology E-ISSN 0976-3945

process and for this, some statistical tool, and Lothongkum, G. et.al. (1999) TIG Pulse
welding of 304 L austenitic stainless steel
Tuguchi method can be applied. in flat, vertical and overhead positions,
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