A Novel Hybrid Welding Process to Improve the Welded Joint Quality of Aluminum Alloys

A significant problem in welding aluminum alloys is the formation of porosity in the weld metal which reduces mechanical properties and usage. The aim of this research is to study the feasibility of developing a welding technique using the hybrid welding process to improve weld quality by minimizing porosity in the weld metal. The hybrid welding process comprises two welding processes: GMAW and GTAW. Metal transfer, weld pool behavior, and oxide cleaning action effect are observed using a high-speed camera. Radiographic testing is also used to evaluate the weld metal's porosity. The results show that the number of porosities significantly decreased. In addition, this study also proposes a detailed selection of welding variables and equipment installation to obtain acceptable weld quality.