Materials Today: Proceedings xxx (xxxx) xxx

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Materials Today: Proceedings

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EXperimental investigation and optimization of Aluminium 6061 by using

various welding process – A review
Harsha Vardhan Thigulla , Varikuppala Pranay Kumar , G Teja Yadav , Bandhavi Challa *
Department of Mechanical Engineering, Gokaraju Rangaraju Institute of Engineering and Technology, Hyderabad, Telangana 500090, India

A R T I C L E I N F O
A B S T R A C T
Keywords:
Aluminum 6061 The current study presents a detailed overview of the research on the application of diverse welding processes for
Tensile Test Aluminium 6061.The study uses a combination of experiments and simulations to determine the most effective
Orientation welding process for producing high-quality joints in Aluminium 6061. It evaluates the various welding methods
Temperature
that have been used to join Aluminium 6061 and provides a critical analysis of the welded connections’
microstructure and mechanical qualities. In order to examines the effect of various welding parameters on these
properties. The results of this study have important implications for the welding of Aluminium 6061 and could
guide the optimization of processing strategies to produce high-quality welds with improved mechanical per-
formance including welding parameters, environmental conditions, and material properties. The paper concludes
with a discussion of the opportunities and challenges for future research in this field. The study is expected to
provide valuable insights into the use of Aluminium 6061 for various applications and to contribute to the
development of more effective welding processes for this material.

1. Introduction
The objective of this review article is to examine the current litera-
ture on the experimental investigation and optimization of Aluminium
6061 using various welding processes. Because of its high strength-to-
weight ratio, superior formability, and great corrosion resistance,
aluminium 6061 is widely employed in a variety of sectors. However,
welding Aluminium 6061 can be challenging due to its tendency to
crack and deform during the welding process. Due to its wide
availability and many uses, aluminium alloy and aluminium metals are
used in almost all modern manufacturing applications. An alloy is a
type of metal that is made by miXing two or more metals to improve
their properties. In the
process of alloying, certain “alloying” metals are added to a core metal
to provide it with specific characteristics, such as improved strength,
corrosion resistance, conductance, hardness, and etc., or an
integration
of these characteristics. Alloys with low alloying element percentages
(about 4%) are called “wrought alloys”. Alloys with higher percentages
of alloying elements (about 22%) are called “cast alloys,” and they are
typically fragile. The Aluminium Association knows the most about
aluminium alloys and has come up with a four-digit naming system for
distinguishing different wrought alloys based on the main elements
that make them up.(See Figs. 1-4).
1.1. Physical properties
Alloy 6061 aluminium is a member of the 6 XXX aluminium alloys
composed primarily of magnesium and silicon. The second number
shows how well the base aluminium is controlled for impurities. If the
second digit is a “0,” it means that most of the alloy is commercial
aluminium with its own level of impurities, and there is no need to take
extra care to tighten controls. The 3rd and 4th numbers are merely codes
for each alloy (Note that 1 XXX aluminium alloys are an exception to this).
Type 6061 aluminium is made up of 97.9% Al, 0.6% Si, 1.0% Mg, 0.2%
Cr, and 0.28% Cu by weight. Aluminium 6061 has a density of 0.0975
lb (0.27 g/cm3). Aluminium 6061 can be treated with heat, is easy to
shape and weld, and is effective at preventing corrosion.
1.2. Mechanical properties
The way 6061 aluminium alloy is heat treated, or made stronger
through the tempering process, changes how it works. To make this
article easier to understand, the strength values for this alloy will be
taken from T6 tempered 6061 aluminium alloy (6061-T6), which is a
common temper for aluminium plate and bar stock. It has a shear
modulus of 26 GPa and a modulus of elasticity of 68.9 GPa (10,000
ksi)

* Corresponding author.
E-mail address: challa.bandhavi@gmail.com (B. Challa).

https://doi.org/10.1016/j.matpr.2023.10.097
Received 15 June 2023; Received in revised form 6 October 2023; Accepted 14 October 2023
2214-7853/Copyright © 2023 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the 14th International
Conference on Materials, Processing & Characterization – ICMPC 2023.
Please cite this article as: Harsha Vardhan Thigulla et al., Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2023.10.097
 H. Vardhan Thigulla et Materials Today: Proceedings xxx (xxxx)

(3770 ksi). Table 1 shows these values, which are used to measure how
stiff or resistant to change the alloy is. This alloy is easy to weld
together and can be easily shaped into most shapes. This makes it a
versatile material for making things.

1.3. Applications

One of the most common types of aluminium alloy is 6061

aluminium. It is good for many general purpose uses because it can be
welded and shaped. Due to its excellent strength and corrosion resis-
tance, Al 6061 alloy is often used for architecture, building structures,
and cars. It has a very long list of uses, but here are some of the most
important ones:

• Heat EXchangers
• Heat Sinks
• Chemical equipment
• Marine frames
• Electronic parts
• Welded-together parts
• Marine frames
Fig. 2. Grain Directions.
• Fasteners
• Frames for planes and trucks
• Furniture

Aluminum 6061, like 6061 aluminium plates, is often used in the

production of cars where fiXtures for production lines are needed. 6061
alloy is utilized in the construction of submersible pumps, fishery lines,
electrical connections, image sensors, ships, motorbikes, chassis,
braking components, compressors, and couplings. Large roof structures,
like those found on bridge decks and in stadiums, are frequently made
from this particular aluminum-magnesium-silicon alloy.
Hot forging is a process that is often used on 6061 aluminium, such as
6061 aluminium plate and extruded bar. In a closed die process, billets
are heated in an induction furnace and then forged. A vast variety of
machinery, including those for ATVs and vehicles, are produced through
the forging process.

1.4. 6061 Aluminum sheet

Aluminum alloy 6061 T6 sheet is one of the most used things in the
world. The T6 in this name speaks of the alloy’s hardness level, or
temper. This is done through a process called precipitation hardening.
This alloy can be changed with heat and has a good ratio of strength to
weight. This aluminium alloy is used to make furniture, boats, and
other things because it is easy to weld and shape.
2. Literature review
The paper “Effect of welding processes on tensile properties of
AA6061 aluminum alloy joints” by K. Elangovan, V. Balasubramanian,
Fig. 3. Testing Specimens.
and A. K. Lakshminarayanan, investigates the effect of various welding
methods on the strain characteristics of Al 6061. The purpose of the
research is to compare the impact of TIG, GTAW, and GMAW on the
mechanical qualities of welded joints.The results of this study can pro-
vide valuable insights into the optimization of welding processes for
AA6061 aluminum alloy and help in in the enhancement of the me-
chanical characteristics of welded aluminium systems [1]. The paper
“Effect of welding process on mechanical and metallurgical properties of

Fig. 1. Welding

2
 H. Vardhan Thigulla et
AA6061 aluminum alloy lap joint” by K Ramachandran and M Arun,
examines the impact of various welding methods on metallurgical and
mechanical features of aluminium alloy joints are formed made from
6061-T6. The study compares the effects of GMAW and GTAW proper-
ties of the welded joints, including their strength, ductility, and micro -
structure. The findings of this investigation can provide important de-
tails about the optimization in welding processes for AA6061
aluminum alloy lap joints and help to enhance the metallurgical and
mechanical
qualities of aluminium welded structures [2]. The paper “A Comparison
Study of Mechanical Properties among Friction Stir Welding and TIG
Welded Joints of Aluminum Alloy (Al 6061-T6)” by Hassan Hady Abd
and Dr. Muna Khethier Abbass equates the physical characteristics of
FSW and TIG Al 6061-T6 aluminium alloy welded joints. The study aims
to analyze FSW’s performance in comparison to TIG welding, with a
focus on fundamental qualities like strength properties, microstructure
and ductility. The findings of this investigation can provide useful in-
formation for selecting the most appropriate welding process for Al
6061-T6 aluminum alloy and can help in improving the quality of
welded aluminum structures [3].
The paper “Brazing 6061 aluminum alloy with Al-Si-Zn filler metals
containing Sr” by Song-bai Xue, Bo Sun, Jiang Lou, Wei Dai, Shui-
qing
Wang, and Feng Ji, emphasized the study of the brazing behavior of
Al alloy 6061 using Sr-containing Al-Si-Zn filler elements. The purpose
of this research is to look into the influence of Sr insertion upon this
machinability and microstructure of a brazed junction. The findings of
this investigation can indeed be beneficial to the development of new
brazing techniques for aluminum alloys and can deliver insights into
the behavior of Sr-containing Al-Si-Zn filler elements [4]. M. Ishak and
L. H.
Shah’s work, “Review of Research Progress on Aluminum-Steel Dis-
similar Welding,” is a review of the literature that summarises the state
of knowledge and research progress mostly on subject of welding dis-
similar materials like aluminium and steel. The authors analyze
existing studies and research papers to identify areas for further
investigation and provide insights into the challenges and limitations
of welding these
two materials. The article was accepted on December 18, 2013, and
published online on July 18, 2014. It appeared in the pages 928–933 of
the journal in which it was published [5]. The article “A Comparison
Study of Mechanical Properties between Friction Stir Welding and TIG
3
Materials Today: Proceedings xxx (xxxx)
Table 1
Mechanical Properties of 6061 aluminium alloy.
SNo Material Properties Weight percentage
1 Elastic Modulus 68.9 GPa
2 Shear Modulus 26 GPa
3 Ultimate Tensile Strength 310 MPa
4 Tensile Yield Strength 276 MPa
5 Shear Strength 207 MPa
6 Fatigue Strength 96.5 MPa
Welded Joints of Aluminum Alloy (Al 6061-T6)” by Drs. Hassan Hady
Abd and Muna Khethier Abbass is a study that compares the
mechanical qualities of connections made by two distinct welding
processes: TIG
and FSW. This study focuses on aluminum alloy Al 6061-T6, and com-
pares the strength, toughness, and other mechanical parameters of the
welded joints produced by the two procedures [3]. The article “Resis-
tance Element Welding of 6061 Aluminum Alloy to Uncoated 22MnMoB
Boron Steel” by Zhen Luo, Yang Li and Zhanxiang Ling is a research
project that looks into using resistant component welding to combine
6061 Al alloy and uncoated 22MnMoB boron steel. To assess the feasi-
bility and effectiveness of this welding procedure, the authors study the
microstructure and mechanical properties of the welded connections
[6].
The article “Study of Welding process parameter in TIG joining of
Aluminum Alloy (6061)” by A. Chiranjeevi, Pramod Kumar,Akhilesh
Kumar Singh, Abdul Arif, V.S. Prasad, Puli Danaiah, Mohan Patro, K.
M. Murugan and Sivarama Kishore is a research that examines the impact
of various welding method parameters on quality of TIG welding of
aluminum alloy 6061. To find the ideal process parameters for pro-
ducing high-quality welds, the authors analyse the welded microstruc-
ture along with the mechanical characteristics of the welded joints. The
study aims to provide insights into the Aluminum alloy 6061 TIG
welding and guide future research in this field [7]. The article “Appli-
cation and use of different alloys of aluminium with respect to work-
ability, strength, and welding parameter optimization” by Kaushal
Kumar and Deekshant Varshney (2021) is a study that examines the
implementation and utilisation of various al alloys with a focus on
optimization of strength, workability, and welding parameters. The
H. Vardhan Thigulla et Materials Today: Proceedings xxx (xxxx)

Fig. 4. UTM Test setup.

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 H. Vardhan Thigulla et Materials Today: Proceedings xxx (xxxx)

authors analyze the properties and features of various aluminum processing. Porosity occurs when hydrogen bubbles become trapped in
alloys, including 6061, 5083, and 7075, and examine their suitability molten
for various applications. The study aims to provide a comprehensive
sum- mary of its use of various al alloys and to guide the selection and
opti- mization of welding parameters for these compostions [8]. The
headline
“Origin of grain orientation during solidification of an aluminum alloy”
by T. DebRoy, J.W. Elmer, and H.L. Wei is the study that investigates the
process through which grains in an alloy of aluminium solidify. The
authors investigate the mechanisms and processes that determine
grain orientation in aluminium alloys using a combination of experiments
and simulations during solidification. The findings of this study have
important implications for the characteristics and microstructure of
aluminium alloys and could guide the development of new processing
strategies to control grain orientation in these materials [9]. The article
“Effect of grain orientation on deformation structure in cold-rolled
polycrystalline aluminum” by N. Hansen, D. Juul Jensen, and Q. Liu
investigates the connection between the deformation structure and grain
orientation in cold-rolled polycrystalline aluminium. The authors use a
combination of experiments and simulations to research the impact of
grain orientation on behaviour of aluminium alloys when deformed
during cold rolling. The study was conducted at the Risù National Lab-
oratory in Denmark’s Materials Research Department. The findings of
this study have important implications in terms of mechanical qualities
and performance alloys of aluminium and could guide the optimization
of processing strategies to control grain orientation and improve the
mechanical performance of these materials [10].
The article “Effect of weld parameters on mechanical properties and
tensile behavior of tungsten inert gas welded AW6082-T6 aluminum
alloy” by The study by Saulius Baskutis, Jolanta Baskutiene, Regita
Bendikiene, and Antanas Ciuplys analyses the effect of welding condi-
tions on the mechanical characteristics and tensile behaviour of TIG
welded AW6082-T6 aluminium alloy. The authors investigate the
microstructure and mechanical properties of welded joints in order to
discover the best procedure parameters for producing high-quality
welds. The study’s goal is to provide insight into TIG welding of
AW6082-T6 aluminium alloy and to guide future research in this area
[11]. The study “Effect of annealing temperature on tensile fracture
behaviour of AZ31/6061 explosive composite plate” by Jian Zhang,
Lifeng Ma, Guanghui Zhao, Zhihui Cai, and Chenchen Zhi investigates
the effect of annealing temperature on the Tensile fracture characteris-
tics of an explosive AZ31/6061 composite plates. The authors use a
combination of experiments and simulations to study the effect of
annealing temperature about the microstructure and mechanical prop-
erties of composite plates. The findings of this study have important
implications for the development of high-performance composite ma-
terials and could guide the optimization of processing methods for
improving the mechanical characteristics of these materials [12]. The
study by T.V. Christy, N. Murugan and S. Kumar, titled “A
Comparative Study on the Microstructures and Mechanical Properties
of Al 6061 Alloy and the MMC Al 6061/TiB2/12P” compares Al
6061 alloy mi-
crostructures and mechanical characteristics, as well as metal matri X
composite Al 6061/TiB2/12P. The study investigates the effect of the
addition of TiB2 particles about the microstructure and mechanical
properties of Al 6061 alloy. The results the study provide important
insights into the potential applications and benefits of using metal ma-
triX composites in various fields, including aerospace, transportation,
and construction [13].

3. Difficulties to weld aluminium

High thermal conductivity: As a result of the extreme heat dispersion

caused by this, welding may be challenging or may result in unwanted
piece distortion.
Hydrogen dissolution rate: Due to the fact that hydrogen is
completely soluble in molten alloy, the weld bead absorbs at hydrogen

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 H. Vardhan Thigulla et Materials Today: Proceedings xxx (xxxx)
material as it solidifies. prod- ucts that require the use of TIG welded aluminium alloys.
Porosity: Porosity occurs when hydrogen gas becomes trapped
inside the securing aluminium weld pool, resulting in voids in the 3.2. Best welding processes for Aluminium 6061
final weld. The potential for excessive porosity during aluminium arc
welding is rather high since hydrogen seems easily soluble in MIG welding can be used to join aluminium alloys properly.
aluminum matriX. While the welding process, impurities in the Because the amount of heat required is less for materials with
welding region might easily enter Hydrogen accidentally. It is critical thinner gauges,
to thoroughly understand the different origins of these impurities in
the search for the source and adopt the appropriate steps to address
porous problems.
Oxide layer: The melting temperature of the oXide layer in
◦
aluminium alloys is much greater (2060C ) than that of the parent
◦
alloy (660C ). During welding process, this might produce the
inclusion of the a
coating of oXide in the weld area, theoretically creating integration
flaws to lower the weld power. As a result, before to welding, To avoid
oXide inclusion, the workpiece should be cleaned with a wire brush
or chemical etching.

3.1. Welding process on aluminium alloys

More than any other metal, aluminium and its alloys can be
bonded in many ways. However, there are some physical and
chemical charac-
teristics of aluminium that are crucial to comprehend while utilizing
the various joining methods. Aluminum’s oXide, electrical, thermal,
and nonmagnetic properties, as well as the fact that it doesn’t change
colour when heated, Moreover, welding is impacted by the wide
range of me-
chanical qualities and melting temperatures that result from alloying
it with other metals, such as oXidation, hydrogen solubility, electrical
conductivity, thermal characteristics, forms of aluminium, and filler
alloy selection criteria. Most welding applications start with how easy
it is to weld. In principle, welding can be done with aluminium alloys
that cannot be heated using a filler alloy that shares the same
primary components as the base alloy. The metallurgically more
challenging and
more prone to “hot short” cracking thermal aluminium alloys melt
the high - temperature zone (HTZ) while welding, which results in
“hot short” cracking. In this situation, different filler alloys with larger
solute contents (such silicon or copper) are frequently utilized.
A crucial topic of research in the world of materials science and
engineering is the investigation of the impact of weld parameters [11]
on the mechanical characteristics and tensile behaviour of tungsten inert
gas (TIG) welded AW6082-T6 aluminium alloy. In many engineering
applications, such as aerospace, automotive, and construction, the
me-
chanical characteristics and tensile behaviour of TIG welded
aluminium alloys are significant. This literature review’s goal is to
give readers a broad overview of what is currently known about
how weld settings
affect the mechanical characteristics and tensile behaviour of TIG-
welded AW6082-T6 aluminium alloy. To provide a thorough
overview of the subject, the researchers most likely undertook a
thorough study of the body of existing literature in the area. Based on
the literature review, The methods by which weld variables, like
welding speed, current, and electrode diameter, impact the tensile
behaviour and mechanical char- acteristics of TIG welded aluminium
alloys were probably covered by the authors. They might have
compared the results of different studies to identify any trends or
inconsistencies in the data. Additionally, the au- thors might have
discussed the limitations of existing research and suggested areas for
future investigation. Overall, this literature review is an important
contribution to the field of materials science and engi- neering, as it
provides a comprehensive understanding of the impact of weld
parameters the mechanical characteristics and tensile properties of TIG
AW6082-T6 weld aluminium alloy. This information can be useful
for engineers and researchers who are designing and developing

6
 H. Vardhan Thigulla et Materials Today: Proceedings xxx (xxxx)

such as aluminium sheet the method is best suited for them, pure composites.
Argon is the best shielding gas., and the welding wire/rod used should
be as identical in composition to the items have been welded as
possible.
TIG welding is also capable of connecting aluminium alloys.
Because of bulk aluminium’s superior thermal conductivity, the TIG
process may create enough heat to keep the weld zone hot enough to
form a weld. TIG
welding is capable of joining thick and thin pieces. Pure argon, like
with MIG welding is the recommended The welding wire/rod utilised,
as well as the shielding gas, should be chemically equivalent to the
pieces being welded.
Resistance spot welding the ratio of steel to aluminium alloy without
filler is impractical and results in very low power as compared to
employing an appropriate file stuff in between. 2- Due to copper’s su-
perior affinity for both metals, the copper filler produced greater
weldment strength than the zinc filler, whereas zinc needed higher
current for a longer period of time to overcome zinc’s inferior affinity
for steel.

4. Effect of orientations

The study of grain orientation [9] is important because it has a

substantial influence on the mechanical properties of the final
solidified material. One theory that has been proposed is the columnar to
equiaxed transition (CET) model, which states that the grain
orientation is determined by the competition between thermal
convection and solid- ification. In columnar solidification, the grains
tend to grow in the di- rection of heat flow, resulting in a preferred
orientation[10]. In contrast, in equiaxed solidification, the grains grow
in a more random manner. The CET model predicts the conditions
under which the transition from columnar to equiaxed solidification
occurs. Another theory that has been explored is the solidification
microstructure model, which takes into account the influence of
microstructural features such as dendritic spacing and secondary
dendrite arm spacing on the grain orientation. According to this
hypothesis, the grain orientation is influenced by the size, shape, and
spacing of the solidifying dendrites. E Xperiments were carried out to
investigate the cause of grain orientation during solidifi- cation of
aluminum alloys[9]. These studies have used techniques such as
optical and electron microscopy, X-ray diffraction, and neutron
diffraction to study the microstructure of the solidified material and
determine the grain orientation. These studies have confirmed the CET
model and the solidification microstructure model and have provided
additional insight into.

5. Effect of temperature for tensile testing

The influence of the annealing temperature [12] of the tensile frac-

ture AZ31/6061 explosive behaviour of composite plates is an
important topic in study of engineering and materials science. Usually,
high- strength applications like aeronautical and automotive industries
use this kind of composite material. The annealing procedure has the
po-
tential to change the material’s fracture behaviour while also enhancing
its mechanical qualities.
Based on the literature review, the authors likely discussed the
mechanisms by which temperature during annealing affects the tensile
fracturing patterns of the hybrid substance. They might have also
compared the results of different studies to identify any trends or in-
consistencies in the data. Additionally, the authors might have discussed
the limitations of existing research and suggested areas for future
investigation.
Eventually, this literature review is an important contribution to
the field of materials science and engineering, as it provides a
comprehen- sive understanding of the influence of temperature on the
welded joints characteristics of AZ31/6061 volatile laminated

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 H. Vardhan Thigulla et Materials Today: Proceedings xxx (xxxx)
6. Conclusions

The study of various welding techniques such as Friction Stir

Weld- ing, TIG welding, Resistance Element Welding and others on
Al 6061 alloy showed the impact in terms of welding parameters and
techniques of the microstructures, mechanical properties, as well as
tensile char- acteristics. The results showed that Friction Stir Welding
results in better mechanical properties than TIG welding while
resistance element welding showed successful joining of Al 6061 with
uncoated 22MnMoB boron steel. Grain orientation and annealing
temperature also play a significant role in the tensile fracture
behaviour of Al 6061 alloys. When compared to Al 6061 alloy, the
microstructures and mechanical char- acteristics of Al
6061/TiB2/12P composite improved.

1. The results of the studies suggest that welding processes have a

significant impact on the tensile characteristics of AA6061
aluminium alloy joints.
2. The welding procedure has an effect on the mechanical and
metal- lurgical qualities of an aa6061 aluminium alloy lap joint.
3. Friction stir welding and TIG welding have different effects
regarding the mechanical characteristics of aluminum alloy (Al
6061-T6) fittings.
4. The addition of Sr to Al-Si-Zn improves the brazing strength of
6061 aluminium alloy.
5. A summary of the progress of research on aluminum-steel
dissimilar welding shows that there are still many challenges to
overcome, including developing appropriate welding processes
and filler ma- terials to achieve strong, high-quality welds
between dissimilar metals.
6. Further research is needed to fully understand the impact of
welding methods on the mechanical characteristics of AA6061
aluminium alloy joints.

7. Scope for future work

The majority of the mentioned research papers appear to be con-

cerned with the influence of various welding methods (such as TIG
welding, Friction Stir Welding, and Resistance Element Welding) on
the tensile properties of AA6061 aluminium alloy joints. Additional
studies look at how annealing temperature, grain orientation, and
filler metals affect the mechanical properties of aluminium alloys.
The microstruc- tures and mechanical properties of Al 6061 alloy and
Al 6061/TiB2/12P metal matriX composite are compared in some
investigations.
Based on these studies, there is scope for further research in the
following areas:

1. Welding parameter optimization for enhanced mechanical

charac- teristics of aluminium alloy joints.
2. Investigation into the effect of various filler metals on the mechanical
properties of aluminium alloy joints.
3. EXamine the influence of annealing temperatures on the tensile
characteristics of aluminium alloys.
4. Investigation of the impact of grain orientation on the
deformation structure and mechanical characteristics of
aluminium alloys.
5. Investigation of the microstructures and mechanical
characteristics of various aluminium alloys and composites.
6. Study of dissimilar welding of aluminium and steel, as well as
opti- mization of welding parameters for improved joint
mechanical properties.
7. Investigation of the influence of welding settings on the
mechanical characteristics and tensile behaviour of aluminium
alloys.
8. Research and development of innovative welding procedures for
aluminium alloys to improve mechanical qualities and reduce
cracking risk.

8
 H. Vardhan Thigulla et
CRediT authorship contribution statement
Harsha Vardhan Thigulla: Conceptualization, Methodology, Soft-
ware. Varikuppala Pranay Kumar: Data curation, Writing – original
draft. G Teja Yadav: Visualization, Investigation. Bandhavi Challa: .
Declaration of Competing Interest
The authors declare that they have no known competing financial
interests or personal relationships that could have appeared to
influence the work reported in this paper.
Data availability
No data was used for the research described in the article.
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