MIG WELDING ( METAL INERT GAS ) USING FEM

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ANALYSIS OF MIG WELDING ON THE
BEHAVIOUR OF ALUMINIUM PLATES USING
FEM
ABSTRACT
Metal Inert Gas Welding is a technique that utilizes a consumable welding tool, the basic principle
of MIG Welding is that an arc is maintained between the end of the bare wire electrode and the
work piece where the heat source required to melt the parent metal is obtained. The purpose of this
work was to obtain a joint of Aluminum plates of AA6063. The principal advantage of MIG
welding is that it has high productivity rate, faster and continous welding speed and improved
quality of weld is obtained .MIG can be used to produce butt, corner, lap, T, fillet joints, as well
as to weld hollow objects, such as tanks and tubes or pipes, stock with different thickness, tapered
sections and parts with 3-D contours. The joints were obtained by MIG welding process, on Gas
Metal Arc Welding Transpulse Synergic Machine. Samples were prepared by taking different
welding process parameters (voltage, amperage, wire feed rate, arc length). Hardness Test, Impact
Test, Tensile Test were conducted to demonstrate a good performance of joint. The
CatiaV5modelling software is used to determine various stresses on work piece. Experimental
results and theoretical results were compared to verify the outcomes. This document reviews some
of the MIG welding work performed to date, presence of brief account of mechanical testing of
welded joints. GMAW has also been used as a low-cost method to 3-Dprint metal objects.
Various open source 3-D printers have been developed to use GMAW. Such components
fabricated from aluminum compete with more traditionally manufactured components on
mechanical strength. The method has gained popularity, since it requires lower heat input and can
be used to weld thin workpieces, as well as nonferrous materials.

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TABLE OF CONTENTS
CERTIFICATE………………………………..…………………………….... ii
DECLARATION…………………………………………………………….. iii
ACKNOWLEDGEMENT…………………………………………………… iv
ABSTRACT…………………………………………………………………...v
TABLE OF CONTENTS……………………………………………………. vi
LIST OF TABLES……………………………………………………...........ix
LIST OF FIGURES…………………………………………………….......... x
LIST OF GRAPHS……………………………………………………….… xii
CHAPTER 1 GENERAL INTRODUCTION
1.1 Introduction…………………………………………………………….………………….1
1.2 Types of mig welding ……………………………………………………..………..…..2
1.3 Principle……………………………………………………………………..…………......5
1.4 Advantages……………………………………………………………………..….............6
1.5 Disadvantages…………………………………………………………………...…........…7
1.6 Application of MIG…………………………………………………………………..……8
1.6 selection of material and process…………………………….…………..………...…….10
1.61 Marerial selection……………………………………………………………...……….11
1.62 Composition of Aluminium AA6063……………………………………………...…...12
1.63 Effect of Addition of Alloying Element on Properties of Parent Material………..…...14
1.64 Mechanicalproperties…………………………………………...…………………...…16
1.7 Application of MIG………………………………………………….…………….….....18

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CHAPTER2 LITERATURE REVIEW
2.1 Summary of literature……………………………………………………………..........13
CHAPTER 3EXPERIMENTATION
3.1 Introduction…………………………………………………………………… ……….25
3 .1.1 Specimens made through MIG Welding……………………………………………..26
3.2 Parameter for Butt Joint……………………………………………...……….……...…28
3.2.1 Parameter for butt joint………………………………………………………………..29
3.3 Fillet joint through MIG……………………………….……………………………….30
3.3.1 Parameter for fillet joint…………………………………………………...………….31
3.4 Testing Methods………………………………………………………….…….............33
3.4.1 Hardness Test………...…………………………………………………....………….33
3.4.1.1 Samples before Hardness Test……..……………………………....……..........34
3.4.1.2 Samples after Hardness Test……… ……………………………..…………....37
3.5.2 Tensile Test……………….…………………………….………………..…...............39
3.5.2.1 Samples before Tensile Test………… ……………………..……..…………...40
3.5.2.2 Samples after Tensile Test………………………………………..…….............42
3.5.3 Impact Test……………………………………………………………..…….………43
3.5.3.1 Samples before Impact Test…………………………………………………….45
3.5.3.2 Samples after Impact Test………………………………………...….…………47
3.5.4 Fracture Test…………………………………………………………………………..47
3.5.4.1 Sample before Fracture Test…………………………….…...…...……….……48
3.5.4.2 Sample afterFrature……………………………………………...…….………48
3.5.6 Macro Test…………………………………………………………………………….48
3.5.5.1 Sample macro Test…………………………...………………………………...48

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CHAPTER 4 ANALYSIS
4.1 Analysis of MIG welded joint……………………………………………….…...….….50
4. Analysis of butt joint……………………………………………………………..……….51
4.2.1 Analysis of butt joint max. load 2280 N……………………………………..……….51
4.2.2 Analysis of butt joint max. load 4800 N……………………………………....….….52
4.2.3 Analysis of butt joint max. load 8080 N……………………………………..………..53
4.3 Analysis of fillet joint…………………………………………………………...………54
CHAPTER 5 RESULT AND ANALYSIS
5.1 Introduction……………………………………………………………….……….. …48
5.2 Analysis of weld zone……………………………………….……………………........49
5.2.1 Experimental Results of Hardness Test……………..……..……………………........49
5.2.3 Experimental Results of Tensile Test…………….………..…………………..……..51
5.2.5 Experimental Results of Impact Test………………………...…………...............…..53
5.2.6 Experimental Results of Fracture Test………….....…………...……………….…….54
5.2 Theoritical analysis result ………………………………………………………………55
5.2.1 Analysis result of butt joint at max. load 2280 N……………………………………..56
5.2.2 Analysis result of butt joint at max. load 4800 N……………….……………………..57
5.2.3 Analysis result of butt joint at max. load 8080 N…………….………………………..58
5.3 Analysis result of fillet joint ………………………………………..………….………..59
CHAPTER 6 CONCLUSION…………………………………….…….…....……57
CHAPTER 7 REFERENCES…………………………………...……….......…… 58
CURRICULUM VITAE…………………………………………………………….

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LIST OF TABLES
Table 1.6 Composition of Aluminum Alloy 6063…………………………….….. …… 21
Table 4.2. Parameter for Butt joint……………………………………………….……….31
Table 4.3 Parameter for Fillet Joint………………………………………….…….……...32
Table 5.2 hardness Test result aluminum welded joint………………….….....….……....40
Table 5.3 Tensile Test Result aluminum welded joint…………………..…...….…..........41
Table 5.4 Fracture Test Result aluminum welded joint…………………..…..…….……..42
Table 5.5 Impact Test Result aluminum welded joint…………………………..………...43
Table 5.5 Impact Test Result aluminum welded joint……………………..…….………..43
Table 5.6 Analysis result of butt welded joint at max. load 2280 N……………………...44
Table 5.7 Analysis result of butt welded joint at max. load 4800 N……………...……....45
Table 5.8Analysis result of butt welded joint at max. load 8080 N……………..………..46
Table 5.9Analysis result of fillet welded joint……………………………………………48

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LIST OF FIGURES
Fig 1.1 MIG welding sciometric diagram………………………………………….…....…2
Fig.1.2 MIG Welding tourch schematic diagram…………………………………....…......2
Fig 1.3 : MIG welding used to fabricate the aluminum panels n ship….……………….…4
Fig 1.4 Parent material for welding…………………………………………….………….5
Fig 1.5 MIG used fabricate in the ship building………………………………...….....…..6
Fig 1.6Mig used in the aerospace………………………………………………...…...…...10
Fig. 3.1 Special Set-up for Welding……………………………………………..........…...26
Fig. 3.2 Experimental Set-up……………………………………………………..….…....27
Fig. 3.3 Butt Welded Joint aluminum Plate………………………………………..….......27
Fig. 3.4 fillet Welded Joint aluminum Plate…………………………………….…..……..28
Fig. 3.5Sample 1(before hardness)… ………………………………………….…. …..….34
Fig. 3.6 Universal Testing Machine……………………………………..…………...........36
Fig3.7 Sample(id 1,2,5) Before Tensile Test…………………………………..……….......37
Fig 3.8Sample (id 1,2,5) After Tensile Test………………………………………..……..38
Fig 3.9 Impact testing machine…………………………………………………….……...39
Fig 3.10Sample (id 1,2,5) After Impact Test………………………………………..……39
Fig 3.11Fracture testing machine………………………………………………………….40
Fig 3.12Sample (id 3,4) before Fracture Test………………………………………….….41
Fig 3.13 Sample (id 3,4) After Fracture Test………………………………….…….…....42
Fig 3.14 Macro Test process diagram………………………………………..........……….43
Fig 3.15 Sample (id 4) After macro Test……………………………………..………........44

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LIST OF GRAPH
Graph 4.1 analysis of butt welded joint above graph at max. load 2280…………………50
Graph 4.2 analysis of butt welded joint above graph at max. load 4800………………….51
Graph 4.3 analysis of butt welded joint above graph at max. load 8080………………….53
Graph 4.4 Above graph analysis of fillet welded joint……………………………………54
.

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CHAPTER 1
GENERAL INTRODUCTION
1.1INTRODUCTION
Gas Metal Arc Welding (GMAW) is commonly referred to as MIG welding (Metal Inert Gas
welding). It is also referred to as MAG welding (Manual Metal Arc Welding). The basic principle
of MIG Welding is, an arc is maintained between the end of the bare wire electrode and the work
piece where the heat source required to melt the parent metal is obtained. The arc melts the end of
the electrode wire, which is transferred to the molten weld pool. For a given wire material and
diameter, the arc current is determined by the wire feed rate. The arc and the weld pool is shielded
from the atmospheric contamination by an externally supplied shield gas. Metal Inert Gas (MIG)
welding is a 'flat' arc process (constant) voltage.
The typical GMAW welding gun has a number of key parts—a control switch, a contact tip, a
power cable, a gas nozzle, an electrode conduit and liner, and a gas hose. The control switch, or
trigger, when pressed by the operator, initiates the wire feed, electric power, and the shielding gas
flow, causing an electric arc to be struck. The contact tip, normally made of copper and sometimes
chemically treated to reduce spatter, is connected to the welding power source through the power
cable and transmits the electrical energy to the electrode while directing it to the weld area. It must
be firmly secured and properly sized, since it must allow the electrode to pass while maintaining
electrical contact. On the way to the contact tip, the wire is protected and guided by the electrode
conduit and liner, which help prevent buckling and maintain an uninterrupted wire feed. The gas
nozzle directs the shielding gas evenly into the welding zone. Inconsistent flow may not adequately
protect the weld area. Larger nozzles provide greater shielding gas flow, which is useful for high
current welding operations that develop a larger molten weld pool. A gas hose from the tanks of
shielding gas supplies the gas to the nozzle. Sometimes, a water hose is also built into the welding
gun, cooling the gun in high heat operations.
The wire feed unit supplies the electrode to the work, driving it through the conduit and on to the
contact tip. Most models provide the wire at a constant feed rate, but more advanced machines can
vary the feed rate in response to the arc length and voltage.

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Fig 1.1 Mig
welding sciometric
diagram
Equipment:-The basic necessary equipment is a welding gun, a wire feed unit, a welding power
supply , a welding electrode wire, and a shielding gas supply.
Welding gun and wire feed unitGMAW torch nozzle cutaway image. (1) Torch handle, (2) Molded
phenolic dielectric (shown in white) and threaded metal nut insert (yellow), (3) Shielding gas
diffuser, (4) Contact tip, (5) Nozzle output face.
Fig.1.2 MIG Welding tourch schematic diagram

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1.2 MIG WELDING TRANSFER TYPE
Part of what makes MIG welding what it is, is the transfer of metal, via heat, from the electrode
(or welding wire) to the base metal(s) being welded. There are four different transfer types
available to MIG welders, and each has its benefits, uses, and drawbacks. Each type is a result of
the voltage settings and shielding gases used, so it’s crucial to be aware of how your voltage and
gas selection will interact to generate the transfer type.
Short circuit transfer type:-Short circuit transfer occurs when, as the name suggests, the welding
wire touches the metal(s) being welded. Electricity from the gun courses through the wire and
creates a short circuit. Within the circuit, the welding wire heats up and drips onto the base
metal(s), creating a “puddle” that welds the joint. The welding wire heats and drips multiple times
a second, and the process produces a fast crackling sound, like something frying in a very hot
pan.Short circuit transfer is achieved using a combination of low voltage and a carbon dioxide
shielding gas or gas mixture. One benefit of the short circuit transfer is that the required shielding
gases are less expensive. The limitation is the thickness of the base metals this type of weld can
handle. It’s used on sheet metals or thin metals measuring a quarter of an inch or less – anything
thicker will prevent the low-voltage weld to penetrate the joint well.
Globular transfer:- Globular transfer is similar to short circuit transfer, with the main difference
being the speed and intensity of the dripping from the welding wire to the joint. With a globular
transfer, the wire melts and collects in a “glob” at the end of the wire, dripping into the joint only
a few times per second. Rather than sounding like a sizzle or a crackle, globular transfer
pops. Globular transfer happens with a combination of high voltage and an argon shielding gas or
gas mixture. One benefit of globular transfer is that it can handle welding thicker metals, but a
drawback is that the drops aren’t always easily controlled and can lead to spatter.
Spray transfer:- Spray transfer happens when the welding wire melts into very fine droplets and
sprays, or “mists,” onto the base metals being welded together. A good spray transfer will make a
hissing sound, rather than a crackle or popping sound. Another characteristic of a good spray
transfer is a clean arc from the welding gun to the base metals.Spray transfer is achieved with a
combination of high voltage and an argon shielding gas or gas mixture, though if carbon dioxide
is more than about 15% of the gas mixture, the electrode will never make the transition from
globular to spray, no matter how high the voltage goes. This type of transfer is often preferred for
welding thicker metals because, when done correctly, it has no spatter. The shielding gas or gas
mixture can be expensive due to the high argon content, however.
Pulstransfertype:-Pulsed spray transfer, unlike the other transfer types, requires a high-end welder.
The welder, when set to pulse, pulses the voltage instead of providing the usual steady flow of

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voltage. The pulses occur many times a second, and the result is a transfer that alternates between
spray and globular transfer. Because the voltage is pulsed, it doesn’t have to be quite as high as
with regular spray transfer. This is beneficial because it decreases the overall amount of heat being
applied to the weld, allowing for a smaller, neater weld pool and joint. The smaller weld pool also
allows for greater flexibility with weld positions, making it ideal for welding pipe and other
difficult projects. The main drawback is the greater expense associated with welders that provide
this function.
1.3 PRINCIPLE
The basic principle of MIG Welding is, an arc is maintained between the end of the bare wire
electrode and the work piece where the heat source required to melt the parent metal is obtained.
The arc melts the end of the electrode wire, which is transferred to the molten weld pool. For a
given wire material and diameter, the arc current is determined by the wire feed rate The GMAW
process In its early commercial applications, the process was used to weld aluminum with an inert
shielding gas, giving rise to the term “MIG” (metal inert gas) which is still commonly used when
referring to the process. Variations have been added to the process, among which was the use of
active shielding gases, particularly CO2, for welding certain ferrous metals. This eventually led to
the formally accepted AWS term of gas metal arc welding (GMAW) for the process. Further
developments included the short circuiting mode of metal transfer (GMAW-S), a lower heat
energy variation of the process that permits welding out-of-position and also on materials of sheet
metal thicknesses; and a method of controlled pulsating current (GMAW-P) to provide a uniform
spray droplet metal transfer from the electrode at a lower average current levels.The GMAW
process uses either semiautomatic or automatic equipment and is principally applied in high
duction welding. Most metals can be welded with this process and may be welded in all positions
with the lower energy variations of the process. GMAW is an economical process that requires
little or no cleaning of the weld deposit. Warpage is reduced and metal finishing is minimal
compared to stick welding. The arc length and the current level are automatically maintained.
Process control and function are achieved through these three basic elements of equipment
The MIG process can be used either semiautomatically or automatically. The basic equipment for
any MIG installation consist of the following:

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Fig. 1.3
Progress of the Tool
through joint
1. A welding gun
2. A wire feed motor and associated gears or drive rolls
3. A welding control
4. A welding power source
5. A regulated supply of shielding gas
6. A supply of electrode
1.4 MIG WELDING ADVANTAGES
The weld is protected against oxidation. No slag is produced. The working speed is very high. The
result is lower heat effects of the surrounding material. This procedure can be used in all Welding
positions. Due to these special advantages, it is now the most used welding procedure.
➢ Higher Productivity
➢ Simple and Great Weld
➢ Clean and Efficient versatile
➢ It conducts electricity and heat almost as well as copper.
➢ It is very corrosion resistant in most environments, so it has found wide applications in
marine and chemical environments.
➢ greater deposit rate
➢ Higher welding speed
➢ Better weld pool visibility
➢ Low skill factor required to operate mig welding
➢ Simple to learn
➢ Versatile

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1.5 DISADVANTAGES OF MIG WELDING
Wind susceptibility – metal shielding gas welding cannot take place outdoors. MAG welding
requires a great deal of experience and is not easy to control. In addition, all rust must be removed
from the weld area beforehand. Apart from proper protective clothing, particular attention must
also be paid to strict use of eye protection in proper condition, as the weld flame develops a
noticeably bright arc.
➢ They are costly
➢ Fast Cooling Rates
➢ Unsuitable for Thick Metals
➢ Limited position
➢ Metal Preparation Time
➢ Sensitive to contaminante
➢ Portability
➢ Sensitive to wind
➢ Lack of fusion
➢ Open arc process
1.6 SELECTION OF MATERIALS AND PROCESE
Aluminum copper alloys – 2000 series
Aluminum Manganese alloys - 3000 series
Aluminum silicon alloys – 4000series
Aluminum Magnesium alloys – 5000 series
Aluminum Silicon Magnesium alloys – 6000 series
Aluminum Zinc alloys – 7000 series
Alloying elements in Commercial Al alloys include Cu, Si, Mg, Mn, and occasionally Zn, Ni, and
Cr. The alloying elements may enhance the mechanical properties by Solid solution hardening
Responding to precipitation hardening or Strain hardening by cold work,
T – thermally treated o

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T2 – Annealed ( cast products only)
T3 – Solution heat treated and then cold worked
T4 – Solution heat treated and naturally aged
T5 – artificially aged only
T6 – solution heat treated and then artificially aged
T7 – Solution heat treated and then stabilized
T8 – solution heat treated, cold worked and then artificially aged
T9 – Solution heat treated, artificially aged and then cold worked
T10- Artificially aged and then cold worked
1.6.1MATERIAL SELECTION
The parent material selected in project work is-
Aluminum (Grade AA 6063)
6063-T6
T6 temper 6063 has an ultimate tensile strength of at least 190 MPa (28,000 psi) and yield strength
of at least 160 MPa (23,000 psi). In thicknesses of 3.15 millimetres (0.124 in) or less, it has
elongation of 8% or more; in thicker sections, it has elongation of 10%.
Fig 1.4 Parent material for welding

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➢ AS one of the most commonly used heat-treatable aluminum 6063, AA 6063 is
an aluminum alloy, with magnesium and silicon as the alloying elements. The standard
controlling its composition is maintained by The Aluminum Association. It has
generally good mechanical properties and heat treatable and weldable. It is similar to
the British aluminum alloy HE9.
➢
6063 is the most common alloy used for aluminum extrusion. It allows complex shapes
to be formed with very smooth surfaces fit for anodizing and so is popular for visible
architectural applications such as window frames, door frames, roofs, and sign frames.
Various reasons for selection of parent metals are as follows:-
➢ No shielding gas or filler wire is required for aluminum alloys.
➢ It is very flexible, being applied to joining in one, two and three dimensions, being
applicable to butt, lap and spot weld geometries.
➢ Excellent mechanical properties, competing strongly with welds made by other processes.
➢ Easy availability.
➢ Aluminum alloys are used more to their superior workability and low cost.
➢ The material has enough strength to resist axial pressure and torque.
1.6.2 COMPOSITION OFALUMINUM AA6063
The alloy composition of 6063
➢ Silicon minimum 0.2%, maximum 0.6% by weight
➢ Iron no minimum, maximum 0.35%
➢ Copper no minimum, maximum 0.10%
➢ Manganese no minimum, maximum 0.10%
➢ Magnesium minimum 0.45%, maximum 0.9%
➢ Chromium no minimum, maximum 0.10%
➢ Zinc no minimum, maximum 0.10%
➢ Titanium no minimum, maximum 0.10%
➢ Other elements no more than 0.05% each, 0.15% total
➢ Remainder Aluminium
ELEMENTS Wt.%
Cr 0.1
Cu 0.1
Fe 0.35

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Mg 0.45-0.9
Mn 0.15-0.5
Si 0.2-0.6
Al 97.5
Table 3.1: Composition of Aluminum (Grade 6063)
1.6.3 EFFECT OF ADDITION OF ALLOYING ELEMENT OF PARNT MATERIAL
➢ Alloying elements when added to Aluminum alloys produce effects of precipitation
hardening (age hardening), hardening, dispersion, grain refining, modifying metallic and
inter metallic phases, suppression of grain growth at elevated tempera
➢ ture (e.g. during annealing), wear resistance and other properties. Effects of addition of
various elements in different grades of Aluminum are mentioned as follows:
➢ Copper (up to 6.5%)
➢ Decreases the ductility of the alloys.
➢ Decreases corrosion resistance.
➢ Increases tensile, fatigue strength and hardness of the alloys.
➢ Chromium (up to 0.35%)
➢ Reduces susceptibility of the alloys to stress corrosion cracking.
➢ Supresses the grain growth at elevated temperatures.
➢ Improves ductility And toughness of Aluminium alloy containing Iron and Silicon.
➢ Iron (up to 1.1%)
➢ Increases strength due to formation of Al-Fe intermetallic.
➢ Decreases ductility. In most Aluminium alloys Iron is undesirable impurity.
➢ Magnesium (up to 1%)
➢ Strengthens and hardens the alloy by solid solution hardening mechanism without
considerable decrease of ductility.
➢ In a combination with Silicon or Zinc allows to strengthen the alloy by precipitation
hardening heat treatment (wrought Aluminum-Magnesium-Silicon alloys (6xxx), wrought
Aluminum-Zinc-Magnesium alloys (7xxx), cast Aluminum alloy 356.0, cast Aluminum
alloy 713.0).
➢ Manganese (up to 1.5%)
➢ Increases corrosion resistance.
➢ Strengthens and hardens the alloys by solid solution hardening and dispersion hardening
mechanism.
➢ Improves ductility of Aluminum alloys containing Iron and Silicon.
➢ Improves low cycle fatigue resistance.
➢ Silicon (up to 1.7%)
➢ Improves resistance to abrasive wear.

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➢ Silicon in a combination with Magnesium allows strengthening of the alloys by
precipitation hardening heat treatment.
➢ Increases strength of the alloys.
➢ Improves cast ability of Aluminum alloy due to a better fluidity and lower shrinkage of
molten Aluminum-Silicon alloy.
1.6.4 MECHANICAL PROPERTIES
The mechanical properties of 6063 depend greatly on the temper, or heat treatment, of the
material. [2]
6063-O
Un-heat-treated 6063 has maximum tensile strength no more than 13 MPa (19,000 psi), and no
specified maximum yield strength. The material has elongation (stretch before ultimate failure) of
18%.
6063-T1
T1 temper 6063 has an ultimate tensile strength of at least 120 MPa (17,000 psi) in thicknesses up
to 12.7 mm (0.5 in), and 110 MPa (16,000 psi) from 13 to 25 mm (0.5 to 1 in) thick, and yield
strength of at least 62 MPa (9,000 psi) in thickness up to 13 millimetres (0.5 in) and 55 MPa
(8,000 psi) from 13 mm (0.5 in) thick. It has elongation of 12%.
6063-T4
to 12.7 mm (0.5 in), and 110 MPa (16,000 psi) from 13 to 25 mm (0.5 to 1 in) thick, , and yield
strength of at least 97 MPa (14,000 psi) up to 13 millimetres (0.5 in) and 90 MPa (13,000 psi)
from13 to 25 mm (0.5 to 1 in).
6063-T5
to 13 millimetres (0.5 in), and 130 MPa (19,000 psi) from 13 mm (0.5 in) thick, and yield strength
of at least 97 MPa (14,000 psi) up to 13 millimetres (0.5 in) and 90 MPa (13,000 psi) from13 to
25 mm (0.5 to 1 in). It has elongation of 8%.
6063-T6
T6 temper 6063 has an ultimate tensile strength of at least 190 MPa (28,000 psi) and yield strength
of at least 160 MPa (23,000 psi). In thicknesses of 3.15 millimetres (0.124 in) or less, it has
elongation of 8% or more; in thicker sections, it has elongation of 10%.
Other tempers

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6063 is also produced in tempers T52, T53, T54, T55, and T832, with various improved desired
properties.
1.7 APLICATION
Aluminum has been used to build ship structures since the mid-20th century with an increasing
application in high-speed vessels in the past 20 years. In ship structures made of either steel or
aluminum, stiffened panels, constructed through welding, are mainly used as ship hullgirders and
they are usually designed for axial compressive loads. The MIG process is currently patented by
TWI in most industrialied countries and licensed for over 183 users. MIG welding are used for
the following industrial applications, shipbuilding and offshore, aerospace, automotive, rolling
stock for railways,general fabrication, robotics, and computers.
➢ Shipbuilding
Fig 1.5 MIG welding used to fabricate the aluminum panels n ship
Two Scandinavian aluminum extrusion companies were the first to apply MIG commercially
to the manufacture of fish freezer panels at Sapa in 1996, as well as deck panels and helicopter
landing platforms at Marine Aluminum Aanensen. Marine Aluminum Aanensen subsequently
merged with Hydro Aluminum Maritime to become Hydro Marine Aluminum. Some of these
freezer panels are now produced by Riftec and Bayards. In 1997 two-dimensional friction stir
welds in the hydrodynamically flared bow section of the hull of the ocean viewer vessel The
Boss were produced at Research Foundation Institute with the first portable MIG welding
machine. , Inc. respectively. The Houbei class missile boat has MIG welding welded rocket
launch containers of China Friction Stir Centre. . Various companies apply MIG to armor
plating for amphibious assault ships.
➢ Aerospace

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Fig 1.6Mig Welding is used in
aerospace
➢ Aluminum alloy 6063 is used in:
• Architectural applications
• Extrusions
• Window frames
• Doors
• Shop fittings
• Irrigation tubing
In balustrading the rails and posts are normally in the T6 temper and formed elbows and
bends are T4. T4 temper 6063 aluminum is also finding applications in hydro formedtube
for chassis.
1.8 ANALYSIS
Analyses based on FEM calculations have significantly changed the possibilities of determining
welding strains and stresses at early stages of product design and welding technology development
The numerical simulation of welding processes is one of the more complicated issues in analyses
carried out using the Finite Element Method. This is due to a number of factors. A welding process
thermal cycle directly affects the thermal and mechanical be haviour of a structure during the
process .Obtaining such data requires not only vast knowledge but also access to a wide range of
laboratory examination focused on the mechanical and thermo-metallurgical properties of the
materials used.
SOLID WORKS:- Analysis of mig welded aluminum butt joint and fillet joint using solid works
and then find the mechanical property of the material.In order to carry out stress analysis,
component material data must be known. The standard SOLIDWORKS CAD material database is
pre-populated with materials that can be used bysolid works Simulation, and the database is easily
customizable to include your particular material requirements. Linear stress analysis with solid
works simulation enables designers and engineers to quickly and efficiently validate quality,
performance, and safety—all while creating their design .Tightly integrated with SOLIDWORKS
CAD, linear stress analysis using SOLIDWORKS Simulation can be a regular part of your design
process, reducing the need for costly prototypes, eliminating rework and delays, and saving time
and development cost

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CHAPTER 2
LITERATURE REVIEW
2.1 SUMMARY OF LITERATURE
1.Y. Zha, T. Moan study shows thats. A three-dimensional, two-step thermo-structural nonlinear
finite element analysis was conducted to simulate the welding induced residual stress and
distortion, and heat affected zone in tee-bar aluminum stiffened plates. The welding of the
longitudinal stiffeners to the plate using metal inert gas welding as well as the welding of the
transverse plates to the plate were simulated. Twelve tee-bar aluminum stiffened plates with
various plate slenderness and column slenderness were considered in this study. The buckling
strength, buckling mode, post-buckling behaviour as affected by geometric properties as well as
the welding induced residual stress, distortion and HAZ were studied. Some conclusions stemming
from the study are as follows:
Maximum tensile residual stress developed in the plate due to welding ranged between 72 and
77% of the base metal yield stress while the compressive residual stresses ranged between 18 and
36% of the base metal yield stress. When compared with the column slenderness, the plate
slenderness was shown to have more significant influence on the distribution and magnitude of
residual stress and HAZ. An increase in the plate slenderness resulted in an increase in residual
stress and the tensile stress width. The magnitude of the tensile residual stress developed in the
stiffeners was higher than that of the plate. However, the magnitude of the peak compressive
residual stress was significantly lower than that of the plate.The total width of the HAZ of the plate
in all models ranged between 26 and 56 mm depending on the thickness of the plate, with thinner
plates having larger HAZ width. The height of the HAZ in the stiffeners was observed between 11
and 24 mm.
All models exhibited a “hungry horse” shape distortion in transverse direction and the longitudinal
distortion showed a half-sine wave pattern. The variation of vertical distortion is related to the
moment of inertia of the cross-section where the greater the moment of inertia, the less the
distortion. Overall, the maximum value of the vertical distortion of all models at the mid-width
was around 2.5 mm.
For all geometries of tee-bar aluminum stiffened plates considered, the buckling strength decreased
due to the presence of the longitudinal and transverse HAZ by as much as 10%. The buckling
strength reduction due to the presence of the residual stresses was as much as 16.5%.

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2. P. Rigo, R. Sarghiuta, S. Estefen, E. Lehmann, S.COtelea, I. Pasqualino study shows that
was to validate a non-linear finite eement model for calculation of the ultimate compressive
strength of stiffened aluminum panels.consequently, a calibration assessment was done comparing
the results of contributors that performed an identical analysis with different codes.then,
contributors carried-out finite element analysis to assess the senstivity on the ultimate strength of
welding join types, HAZ witdth, initial panel deflection (amplitude and shape), residual stress,
plate thickness and yield stress in the HAZ. Numerical simulations have shown thate the plastic
buckling analyses of the considered aluminum stiffened panel, which are based on the incremental
theory of plasticity, are significantly sensitive to these parameters.The result from phase A have
led to choice of a new and more appropriate geometry to achieve the sensitivity analyses (phase
B). Phase A shows that HAZ has no significant effect for a slender panel with low ultimate strength
but as the panel becomes stockier and thus experience plasic buckling, the senstivity becomes more
important.
3. T.Wang,O.S. Hopperstad, O.G Lademo, P.K. Larsen study show that Shell element-based
modelling of welded and un-welded I-sections under four-point bending has been assessed. For
both the explicit and implicit analyses.an element size of mm2 appears to give accurate.robust and
efficiency predictions of the structure response of the members.the explicit analysis with the
refined mesh were unsuccessful when using the WTM-2D material model. using the implicit
slover,no significant diference was found between the analysis by coarse and refined meshes for
beams failing by local buckling, while for beams failing by necking mesh dependence was
discovered. homogeneous material property (heat affected zone, HAZ) and geometric imperfection
were seen to cause local buckling to occur earlier .for the explicit analysis, geometric imperfections
were not necessary for reasonable predictions. meanwhile for implicit analysis when the numerical
accuracy needs to be high, geometric imperfection or material inhomogeneity is essential for the
predicts for the predictions to be accurate.it is concluded that the adopted modeling approach,
using shell elements, plastic anisotropy, inhomogeneous material properties in the neighbourhood
of the weld, geometrical imperfections and ductile failure, seems to give satisfactory results should
be expected when failure occure by necking in the HAZ.
4. Harmeet Singh, Harish Kumar, Chander Shakher, Gaurav Jain study shows that On the
basis of experimental investigation carried out on FSWand MIG welded joints of AA 6066, the
following conclusions are drawn The formation of fine, equiaxed grains and uniformly distributed
very fine strengthening precipitates in the weld region is the reason for superior tensile properties
of FSW joints as compared to MIG joints.Tensile test results shows that FSW joints have higher
strength and higher ductility compared to MIG joints. The joint efficiency which is the ratio of
tensile strength of welded joint to the tensile strength of base metal is 3% more in FSW welding
in comparison to MIG welding.Hardness tests confirm the general decay of mechanical properties
induced by higher temperature experienced by material in case of MIG joint.Hardness tests
performed in case of FSW joint shows great differences among four different zones: nugget zone,
TMAZ, HAZ (Heat affected zone) and base metal. The first twozones are characteristized by a

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general drop of mechanical properties, even though nugget zone showed a slight recovery due to
fine grain structure From industrial perspectives, FSW is very competitive because it saves energy
due to less heat input, prevents joints from fusion related defects, is cost effective and has better
strength than MIG joint.
5. Rujira Deekhunthod study shows that that This work has involved analyses in several areas.
From all of the results and observations, some final conclusions are made:
No significant difference in tensile and yield strength could be seen between welded samples from
the different ingots.
MIG welding had an effect on the HAZ-microstructure and the mechanical properties. The HAZ
range was distributed to 20 mm from the fusion line with 5 mm plate thickness.
Hot cracking did not appear during investigations. Weld appearance follows the standard
EN ISO 10042:2005 in quality level C.
Tensile strength of all welded samples joins has similar strength value and all arehigher than
applied standards (SS-En 13981-1).
Yield strength of all welded samples have lower value than standard and that why AA6005A
should not be used when they are welded, according SS-En 13981-1.
In all cases, the fracture in tensile testing is located in the HAZ. Intermetallic phase particles as
Mg2Si and FeAl3 were not seen which meant they may be too small and to find with SEM.
The loss of hardness and tensile strength in the HAZ (at a distance from fusion line about 10-15
mm) is believed to be a result of coarsening of the strengthening beta phase
(AlFeSi).
6. Tomasz Kik study shows that On the basis of the numerical analysis of welding butt joints in
aluminum alloys it was possible to observe that the degree of stiffening an element during welding
and post-weld cooling affects the manner of element deformation and the distribution of post-
weld stresses,in the case of aluminum alloy sheets, deformations are not the consequence of
significant differences in stress values but result mainly from the distribution of stresses in a
welded joint numerical analysis enables faster and cheaper selection of the optimum manner of
fixing elements for welding as well as the precise analysis of stress and strain distributions
resulting from fixing variants analysed, as a result, numerical analysis makes it possible
to significantly reduce prototyping costs and to consider a greater number of possible
solutions without risking additional costs.This method also enables the analysis of difficult
and expensive issues as regards necessary testing equipment
7. W Xu and M F Gittos study shows that An extensive mechanical testing programme has
been carried out on aluminum-silicon and
aluminum-magnesium welds in 6005A-T6 extruded components, employing a range of strain
rates. The analyses of the test results have led to the following main conclusions:
1. The aluminum-silicon weld metal in the extruded plates was poorer than the weld metal
made using aluminum-magnesium filler metal in terms of strength, ductility and fracture
resistance.
2. Under quasi-static loading, the aluminum-magnesium weld metal in the extruded plate
outperformed the parent material in terms of the ultimate strength, ductility and fracture
toughness,but its 0.2% proof strength was lower than the parent material.
3. In terms of the ability to sustain uniform plastic deformation, the HAZ was the worst zone,
as indicated by the smallest amount of elongation at the maximum load. This, coupled with the

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lower strength than the parent material, will cause strain localization in the HAZ.
4. Although the weaker weld metal and the HAZ did not cause complete fractures of the
welded rail vehicle floor extrusions under the predominately compressive mode of loading, the
effects of the weak zones on the performance of welded structural components should be
evaluated against the most damaging loading mode in situations where several loading modes
co-exist.
8. Y.M. Zhang, C. Pan, and A.T. Male studty shows that Compared to bead-on-plate VPPAW
welding of 6061 aluminum alloy, the DSAW process has the following advantages.
1. The percent of equiaxed grains is increased and columnarto-equiaxed grain transition occurs
earlier than in partially penetrated DSAW and VPPAW welds.
2. Hot cracking sensitivity is reduced by minimizing residual stresses in the weld, as a result of
the symmetrical temperature profile produced during double-sided welding.
3. Pores are smaller and more dispersed among the equiaxed dendrites produced by DSAW with
full penetration than in the partially penetrated DSAW and VPPAW welds.
9. K. Störzel T. Bruder, H. Hanselka study shows that Flatter inverse slopes than the inverse
slope k = 3 recommended in were observed in the test results with detail specimens and
components examined. This is why in some cases using the IIW-design SN curves for assessing
the test results leads to non-conservative assessment in the lower cycle range N < 106.The number
of cycles at the kneepoint of the SN curve should be assumed as Nk = 1 _ 107 as recommended
by the IIW guideline.No further information is available for failure cycles NP1 _ 107 due to the
fact that the fatigue tests conducted here were stopped
at the limit cycle number nL = 1 _ 107.When applying the various approaches based on the current
state of the art, approximately similar scatter bands are obtained allowing for the number of test
series considered. However, it should be noted in this case that both the nominal and also the
structural hot spot stress approaches are limited in their use compared to the notch stress approach.
As different numbers of test series were used as the basis for assessing the various approaches, a
comparison of the scatter bands obtained is subject to limitations.
Assignment of the notch case classes of weld details according to the IIW guideline for the
nominal stress approach is confirmed. However, there are specimens that have weld details critical
to failure that cannot be assessed using the nominal stress approach.In addition to external
linearization for extrapolation of the structural hot spot stresses at the weld toe, for the investigated
weldings it also proved possible to assess weld details where an external linearization was
performed towards the root notch. The accuracy of the notch stress approach may be increased or
the scatter bands reduced if – particularly with the reference radius
rref = 0.05 mm – reference SN curves are used for subgroups. The subgroups arise depending on
the failure location (weld toe,weld root) and the R-ratio.The studies show that due to the existing
guidelines, welds are sometimes designed very conservatively. It is possible to optimise
and reliably design welded joints of thin sheet structures with negligible residual stresses by
applying the notch stress approach using the reference radius rref = 0.05 mm and the reference SN
curves derived here. It is possible as a result to achieve a morecost-effective and at the same time
safer design of welded cyclicloaded components. Structures with high residual stresses shouldbe
evaluated with a SN-curve transformed to R = 0.5.

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CHAPTERE-3
EXPERIMENTATION
3.1 INTRODUCTION
In this experiment of MIG, the welding process is suggested to be performed using GMAW Trans
Pulse Synergic machine. For facilitating welding process and to measure welding parameter was
prepared. , the process objective or target values to be optimized are defined for the welding
process. On the basis various research papers, different problem faced during welding of two
aluminum sheets are determined and aluminum AA6063 is selected as parent metal to be welded.
Metal inert gas (MIG) welding uses a consumable wire electrode and shielding gas, which is
continuously fed through a welding gun. Aluminum requires some specific changes for welders
who are accustomed to welding steel. It's a much softer metal so the feed wire must be larger.
Aluminum is also a better conductor of heat,so welding aluminum requires more control over the
power supply and the feed rate of the electrode.1.Select more powerful welding machines for
thicker metal. A 115-volt welder can handle aluminum up to an eighth of an inch thick (3 mm)
with adequate preheating, and a 230-volt machine can weld aluminum that's up to a quarter of an
inch thick (6 mm). Consider a machine with an output greater than 200 amps if you will be welding
aluminum daily.2.Choose the correct shielding gas. Aluminum requires a shielding gas of pure
argon in contrast with steel, which typically uses a blend of argon and carbon dioxide (CO2). This
should not require any new hoses, although you may need to replace regulators that were designed
specifically for CO2.
3.1.1SPECIMENS MADE THROUGH MIG WELDING
Electrode thickness is especially critical with aluminum and there is an extremely narrow range
to consider. Thinner wire is more difficult to feed, while thicker wire requires greater current to
melt. The electrodes for welding aluminum should be .035 of an inch in diameter (less than 1 mm).
One of the best choices is 4043 aluminum. A harder alloy like 6063 aluminum is easier to feed,
but will require more current.
1.Feed the electrodes with an aluminum feeding kit. These kits are commercially available and
will will allow you to feed softer aluminum wire with the following features:
• Larger holes on the contact tips. Aluminum expands more than steel as it’s heated. This
means the contact tips will need larger holes than the ones used

xxv
Fig. 3.1 Special Set-up for Welding
for steel wire of the same size. However, the holes should still be small enough to provide good
electrical contact.
U-shaped drive rolls. Aluminum feeders should use drive rolls that won’t shave aluminum wire.
The inlet and outlet guides for these feeders shouldn’t shave the softer aluminum wire. In contrast,
steel feeders use V-shaped drive rolls, which are specifically designed to shave the wire.
• Non-metallic liners, which will further reduce the friction on the wire as it goes through the
feeder.
2. Keep the gun cable as straight as possible so the wire feeds properly. Softer wire is more prone
to kinks due to feeding restrictions.
3 .2 BUTT JOINT THROUGH MIG WELDING

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Fig 3.2 Experimental Set-up
Fig. 3.3 Butt Weded Joint aluminum Plate
3.2.1 PARAMETER FOR BUTT JOINT

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I D VOLTAGE CURRENT THICKNESS ARC LENGTH
CORRECTION
WIRE
FEED
RATE
1 21.5 V 145 A 6 -2.1 6
2 23.0 V 154 A 6 -2.1 6.5
5 23.6 V 193 A 6 -2.1 8
4.2 Table Parameter for Butt Joint
3.3FILLET JOINT THROUGH MIG

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Fig. 3.4fillateWeded Joint aluminum Plate
3.3.1PARAMETER FOR FILLET JOINT
I D VOLTAGE CURRENT THICKNESS ARC
CORRECTION
LENGTH
WIRE FEED
RATE
3 21.5 V 145 A 6 -2.1 6
4 23.0 V 154 A 6 -2.1 6.5
Table 3.3 Parameter For Fillet Joint
3.4TESTING METHOD
3.4.1 HARDNES TEST
Brinel hardnes test- The Brinell hardness test method consists of indenting the test material with
a 10 mm diameter hardened steel or carbide ball subjected to a load of 3000 kg. For softer materials
the load can be reduced to 1500 kg or 500 kg to avoid excessive indentation. The full load is
normally applied for 10 to 15 seconds in the case of iron and steel and for at least 30 seconds in
the case of other metals. The diameter of the indentation left in the test material is measured with
a low powered microscope. The Brinell harness number is calculated by dividing the load applied
by the surfacearea of the indentation.

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3.4.1.1SAMPLE HARDNES TEST
Fig. 3.5 Sample ( id1,2,5) hardness test

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3.5.2.1 Tensile test-
Tensile testing, is also known
fundamental materials science test in which a
sample is subjected to a controlled tension until
failure. The results from the test are commonly used
to select a material for an application, for quality
control, and to predict how a material will react
under other types of forces. Properties that are
directly measured via a tensile test are ultimate
tensile strength, maximum elongation and reduction
in area.[2]
From these measurements the following
properties can also be determined: Young's
modulus, Poisson's ratio, yield strength, and strain-
hardening characteristics. Uniaxial tensile testing is
the most commonly used for obtaining the
mechanical characteristics of isotropic materials.
For anisotropic materials, such as composite
materials and textiles, biaxial tensile testing is
required.
Fig. 3.6Universal Testing Machine
Tensile Test Specimen :-A tensile specimen is a standardized sample cross-section. It has two
shoulders and a gage (section) in between. The shoulders are large so they can be readily gripped,
whereas the gauge section has a smaller cross-section so that the deformation and failure can occur
in this area.
The shoulders of the test specimen can be manufactured in various ways to mate to various grips
in the testing machine (see the image below). Each system has advantages and disadvantages; for
example, shoulders designed for serrated grips are easy and cheap to manufacture, but the
alignment of the specimen is dependent on the skill of the technician. On the other hand, a pinned
grip assures good alignment. Threaded shoulders and grips also assure good alignment, but the
technician must know to thread each shoulder into the grip at least one diameter's length, otherwise
the threads can strip before the specimen fractures.In large castings and forgings it is common to
add extra material, which is designed to be removed from the casting so that test specimens can be

xxxii
made from it. These specimens may not be exact representation of the whole workpiece because
the grain structure may be different throughout. In smaller workpieces or when critical parts of the
casting must be tested, a workpiSample before tensil test-ece may be sacrificed to make the test
specimens.For workpieces that are machined from bar stock, the test specimen can be made from
the same piece as the bar s
3.5.2.1 SAMPLE BEFORE TENSIL TEST
Fig 3.7 Sample(id A 1,2,5) Before Tensil Test

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3.5.2.2 SAMPLE AFTER TENSIL TEST
Fig3.8Sample (id 1,2,5) AfterTensil Test

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3.5.3 IMPACT TEST CHARPY IMPACT TEST
The Charpy impact test, also known as the Charpy V-notch test, is a standardized high strainrate
test which determines the amount of energy absorbed by a material during fracture. This absorbed
energy is a measure of a given material's notch toughness and acts as a tool to study temperature-
dependent ductile-brittle transition. It is widely applied in industry, since it is easy to prepare and
conduct and results can be obtained quickly and cheaply. A disadvantage is that some results are
only comparative.The apparatus consists of a pendulum of known mass and length that is dropped
from a known height to impact a notched specimen of material. The energy transferred to the
material can be inferred by comparing the difference in the height of the hammer before and after
the fracture (energy absorbed by the fracture event).The notch in the sample affects the results of
the impact test, thus it is necessary for the notch to be of regular dimensions and geometry. The
size of the sample can also affect results, since the dimensions determine whether or not the
material is in plane strain. This difference can greatly affect conclusions made
.
Fig 3.9 impact testing machine
Impact Loading: Impact loading differs from quasi-static loading in that a load is applied over a
very short time instead of being introduced gradually at some constant rate. This causes significant
changes in the observed material properties from those associated with normal static tests. In the
case of impact loading the effects measured are of a dynamic nature, with vibration and possibly
fracture being observed

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3.5.3.1 SAMPLE AFTER IMPACT TEST
Fig 3.10 samples (id 1,2,5) after impact test
3.5.4 FRACTURE TEST
Fracture toughness tests measure a material’s ability to resist the growth or propagation of a pre-
existing flaw. The flaw or defect may be in the form of a fatigue crack, void, or any other
inconsistency in the test material. Fracture toughness tests are performed by machining a test
sample with a pre-existing crack and then cyclically applying a load to each side of the crack so
that it experiences forces that cause it to grow. The cyclic load is applied until the sample’s crack

xxxvi
grows. The number of cycles to fracture is recorded and used to determine the material’s fracture
growth characteristics Fracture toughness is the stress that causes a pre-existing crack or flaw to
grow or propagate. It is an important material property in the manufacturing industry, since the
presence of flaws is not completely avoidable. The stress intensity factor, which is a function of
the flaw size, geometry, and loading, is used to determine a material’s fracture toughness. A
material’s stress intensity factor and fracture toughness are related to one another in the same
manner that stress and tensile stress are related to each

xxxvii
.
Fig:3.11 fracture testing machine

xxxviii
3.5.4.1SAMPLE BEFORE FRACTURE TEST
Fig3.12 Samplse(id3,4) before fracture test
3.5.4.2 SAMPLE AFTER FRACTURE TEST
-
Fig 3.13Samplse (id 3,4) after fracture test

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3.5.5 MACRO EXAMINATION TESTING
Macro etch testing allows the tester to see a cross section of the weld, and see the arrangement of
the grains in the parent metal and the weld material. This is known as its Macrostructure. Its can
also show up defects such as porosity, inclusions and poor fusion. You need minimal equipment
to perform a macro etch test. Firstly, it involves cutting a sample from the welded joint. Cold
cutting methods are best for this, such as a bandsaw.
Then the surface needs to be polished. File away any burrs and rough marks, then use progressively
finer grades of emery until a smooth even polish is obtained.Once prepared, an acid solution is
applied with a soft clean cloth, wiping over the test piece. The acid used is nitric acid, dissolved in
distilled water. The solution is 10% Nitric acid, and 90% water. Nitric acid is used because of its
rapid oxidizing, properties. After a short time, the parent metal and weld areas will begin to
discolour. If it doesn't, it is possible to clean and re-apply the acid solution. If it discolours too
much, it may require re-polishing and reapplication of the acid. Once results are visible, the sample
is rinsed off and carefully dried.
The results should show distinctive colour difference between the actual weld metal and the parent
metal in the immediate area. The weld will show up lighter, and the darker material next to it is
the rearranged grain structure, due to the heating and cooling cycle. In multiple run welds, the one
that is done first shows up slightly darker, due to the root run being reheated during the second
pass.
Fig3.14. Macro test process digram

xl
3.5.6 SAMPLE FOR MACRO TEST
Fig 3.15 Sample after (id 4) macro test
Macro Test result- According to this it was found that the complete fusion of weld to base metal
without any inclusion, porosity, discontinuity and cracks. The depth of penetration is found to be
0.18 mm .

xli
CHAPTER 4
ANALYSIS
4.1 ANALYSIS OF MIG WELDED JOINT
analysis of mig welded joint in solid works software with the using of the Finet element
mehod. Simulations of the welding process for butt and tee joints using finite element analyses are
presented. The base metal is aluminum alloy 6063-T6 and the filler material is alloy ER 4047. The
simulations are performed with the commercial software Solid works.
Solid works
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your costs for live prototypes and testing.
4.2 ANALYSIS OF BUTT JOINT
The butt joint simulation models the joining of two identical plates with rectangular platform and
uniform thickness. The dimensions of one of the two plates of the butt joint model dimension is,
l=150, b=25, t= 6 . Since the two plates to be joined are identical, only one plate is modeled in the
finite element analysis. Welded joint analysis is referred to as a step-by-step computation in solid
works.
4.2.1 ANALYSIS OF BUTT JOINT AT MAX. LOAD 2280 N
Analysis type – Static

xlii
Dimension , length=150mm, breadth=25mm, thickness= 6mm

xliii
Graph 4.1 analysis of butt welded joint above graph at max. load 2280

xliv
4.2.2 ANALYSIS OF BUTT JOINT MAX. LOAD 4800 N

xlv

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4.2.3 ANALYSIS OF BUTT JOINT AT MAX LOAD 8080 N

xlviii
4.3 ANALYSIS OF FILLET JOINT

xlix
Name Type Min Max
Stress VON: von Mises
Stress
1.556e+001N/m^2
Node: 6048
5.611e+004N/m^2
Node: 18807
Part1-SimulationXpress Study-Stress-Stress

l
Graph 4.4 above graph analysis of fillet welded joint
Type Min Max
Displacement URES: Resultant
Displacement
0.000e+000mm
Node: 1181
1.019e-004mm
Node: 718
Part1-SimulationXpress Study-Displacement-Displacement

li
CHAPTER 5
RESULT AND DISCUSSION
We have conducted two types of test one is experimental and the other is theoretical analysis.
Experimental test are conducted on various testing machine in order to find out several stresses on
our work piece. In theoretical analysis we had made model and find analyse them by using CatiaV5
and Solid Work Software.
5.1 EXPEIMENTAL RESULT
Various test are conducted on our work piece to find out the mechanical stresses. The test
conducted by machine are-
➢ Hardness Test
➢ Tensile Test
➢ Impact Test
➢ Fracture Test
➢ Macro Test
5.1.1 HARDNESS TEST RESULT
The following are the brinell hardness number of the specimen.
I D Description of Test Load Observation
1 Brinell Hardness Test 100 kgf 66
2 Brinell Hardness Test 100 Kgf 62
5 Brinell Hardness Test 100 Kgf 64
Table 5.2 hardness of test result aluminum welded joint
5.1.2 TENSILE TEST RESULT
The tensile strength of the welded joints good as expected.

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I D Max Load
(Newton)
Dimensions
(mm)
UTS Location of
Fracture
1 4800 25.04 x 6 31.95 Weld Metal
2 2280 25.62 x 5.92 15.03 Weld Metal
5 8080 24.94 x 6.02 53.82 Weld Metal
Table 5.3 Tensile Test Result aluminum welded joint
5.1.3 FRACTURE TEST RESULT
I D Sample ID Observation/ Result
FT-1 3 Complete Fusion of weld to base metal without any inclusion,
porosity.
Fracture Load – 19.720 KN
Table5.4 Fracture Test Result aluminum welded joint
5.1.4 IMPACT TEST RESULT
I D Description of Test Charpy/Izod Observation
1 Impact Test Charpy 2 J
Table 5.5 Impact Test Result aluminum welded joint

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5.2 THEORITICAL ANALYSIS RESULT
Solid Work software is used to produce 3D model of our butt and fillet joint. Analysis is done by
applying certain amount of loads i.e 2280, 4800, 8080 N on our butt and fillet joints.
5.2.1 ANALYSIS RESULT OF BUTT JOINT AT MAX. 2280 N
Model Reference Properties Components
Name: 6063-T6
Model type: Linear Elastic Isotropic
Default failure criterion: Max von Mises Stress
Yield strength: 2070.1psi
Tensile strength: 2465.1 psi
Elastic modulus: 1.00076e+007 psi
Poisson's ratio: 0.33
Mass density: 0.0975437 lb/in^3
Shear modulus: 3.74197e+006 psi
Thermal expansion
coefficient:
1.3e-005 /Fahrenheit
Solid Body 1(Boss-
Extrude1)(butt joint FINAL
ANALYSIS),
Solid Body 2(Boss-
Extrude2)(butt joint FINAL
ANALYSIS)
Curve Data:N/A
Fixture name Fixture Image Fixture Details
Fixed-1
Entities: 2 face(s)
Type: Fixed Geometry
Resultant Forces
Components X Y Z Resultant
Reaction force(lbf) 0.00755698 1025.13 0.00151791 1025.13
Reaction Moment(lbf.in) 0 0 0 0

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Load name Load Image Load Details
Force-1
Entities: 2 face(s)
Type: Apply normal force
Value: 2280 N
Table 5.6 Analysis result of butt welded joint at max. load 2280 N
5.2.2 ANALYSIS RESULTOF BUTT JOINT AT MAX. LOAD 4800 N
Name: 6063-T6
Yield strength: 4334.1 psi
Thermal expansion
coefficient:
SolidBody 1(Boss-
Extrude1)(butt joint),
SolidBody 2(Boss-
Extrude2)(butt joint)
Curve Data:N/A
Fixed-1
Entities: 1 edge(s), 2 face(s)
Resultant Forces

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Force-1
Entities: 2 face(s)
Value: 4880 N
5.2.3 ANALYSIS RESULT OF BUTT JOINT AT MAX. LOAD 8080 N
Name: 6063-T6
Yield strength: 6940.1 psi
Thermal expansion
coefficient:
SolidBody 1(Boss-
Extrude1)(butt joint),
SolidBody 2(Boss-
Extrude2)(butt joint)
Curve Data:N/A

lvi
Fixed-1
Entities: 1 edge(s), 2 face(s)
Resultant Forces
Force-1
Entities: 2 face(s)
Value: 8080 N
5.2.4 ANALYSIS RESULT OF FILLET JOINT
Name: 6063-T6
Default failure criterion: Unknown
Yield strength: 2.15e+008 N/m^2
Tensile strength: 2.4e+008 N/m^2
SolidBody 1(Boss-
Extrude2)(Part1)

lvii
Table 5.9 Analysis result of fillet welded joint
CHAPTER-6
CONCLUSION
Fixtur
e
name
Fixture Image Fixture Details
Fixed-
1
Entities: 1 face(s)
Load
name
Load Image Load Details
Force-1
Entities: 1 face(s)
Value: 21 kN

lviii
A three-dimensional, finite element analysis was conducted to simulate the welding induced
stresses , with the help of Experiments and Theoretical Analysis using CatiaV5 and solid Works
on Weld Joints of aluminum stiffened plates. The welding of the Butt Joint using metal inert gas
welding as well as the welding of the fillet Joint were simulated. Aluminum stiffened plates with
various temperature change in weld bead were considered in this study.
The ultimate purpose of the project has been achieved with developing techniques of the finite
element analysis of fillet welded joint. The experimental investigation validate the performance of
the FEA analysis results were found 1.2% error on tensile test. The experiment tensile stress on
Butt Joint with load 2280N was found 15.03 MPa and simulation tensile stress at the same location
appears 17 MPa. The experiment tensile stress on Butt Joint with load 4880N was found 31.95
MPa and simulation tensile stress at the same location appears 34.72MPa. The experiment tensile
stress on Butt Joint with load 8080N was found 53.95 MPa and simulation tensile stress at the
same location appears 50.74 MPa.

MIG WELDING ( METAL INERT GAS ) USING FEM

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