PSI - Issue 66

11

S. Skrobacz et al. / Procedia Structural Integrity 66 (2024) 11–25 S. Skrobacz¹², P. Krysi ń ski¹, S. Ma ł ys¹², T. Ł agoda², / Structural Integrity Procedia 00 (2025) 000–000

21

Table 7. Optimization of the Welding Process for EN AW 6060 Aluminum Alloys

No.

Macrographic Cross-Section – Before Optimization

Observations and Optimization

Macrographic Cross-Section – After Optimization

1.

During the execution of the welds, the initial parameters caused evident burn-through and concave formation of the weld face. To optimize the process, modifications were introduced to the welding program and parameters, consisting of a reduction in wire feed rate combined with a decrease in welding current. Additionally, the torch feed rate was reduced. Below, the macrographic cross-sections are presented along with the implemented steps. The initial parameters resulted in slight penetration, and the weld contained cracks. Adjustments were made to the torch position, the wire feed rate was increased, and a dynamic adjustment of the Up Slope parameters was applied. With each subsequent millimeter of the weld, the wire feed rate, current intensity, and torch feed rate were adjusted. The initial parameters did not provide sufficient penetration. The penetration depth was measured at 0.5 mm, which did not meet the requirements for this joint. The weld face was excessively convex, which was unacceptable for subsequent technological processes. To address this, torch oscillation was implemented, and the wire feed rate was reduced.

2.

3.