Development of a novel hybrid welding process of aluminum alloys under different shielding gas composition

Aluminum alloy grade 5083 is widely used in many industries. Welding of Aluminium and its alloys typically presents problems due to aluminum-oxide films. The main problem is porosities in weld metal which affects its mechanical properties and applications. Therefore, this research aims to study the effect of shielding gas composition on oxide cleaning action of hybrid welding process that combines Gas Tungsten Arc Welding (GTAW) and Gas Metal Arc Welding (GMAW). The welded specimens are evaluated by using microstructure analysis and inspected by radiographic testing to determine weld quality and the amount of porosity. A high-speed camera also analyzes metal transfer patterns and oxide cleaning action. It was found that the suitable shielding gas type and shielding gas composition significantly improve the welding quality and improve the weld bead appearance of aluminum welding.