Weld quality improvement using GMAW–GTAW hybrid welding process for aluminum alloy

One of the primary challenges in welding aluminum alloys is the formation of porosity in the weld metal, which adversely affects mechanical properties and overall usability. This study aims to evaluate the feasibility of a hybrid welding technique designed to improve weld quality by minimizing porosity. The hybrid process combines gas metal arc welding (GMAW) and gas tungsten arc welding (GTAW). High-speed video analysis was conducted to examine metal transfer, weld pool behavior, and oxide cleaning action. Radiographic testing was employed to assess the porosity in the weld metal. The experiments were carried out using AA5083 plates, with a welding current of 200 A, an arc voltage of 30 V, and travel speeds of 45, 55, and 65 cm/min. The results indicate a substantial reduction in porosity, with a remarkable decrease of up to 93% following the GMAW-GTAW hybrid welding process. Additionally, the appearance of the weld bead was significantly enhanced, featuring a clean, spatter-free surface with smooth ripple patterns.