Author : Sagar R.Chikhale, Kishor P.Kolhe and Pawan Kumar

Aluminum and its alloys are having variety of applications in today’s industrial scenario. The use of Al and its alloys are increasing day by day due to its specific properties, like light weight, high strength, and excellent corrosion resistance. Present study is conducted on Aluminum 6061 tempered alloy by using semi automatic MIG welding Machine with current range 10A-420A and voltage range 10V-41V.The studies are carried out by using British Welding specification; nine samples were prepared for toughness studies and tensile strength. The CVN samples were prepared by ASTM-E-23 standard. Also tensile specimens were prepared by using ASTM-E28/E8M-09 for identifying the tensile strength of weld specimen. The testing was carried out by using Universal testing machine with hydraulic grip. However the fracture toughness studies were carried out by using Charpy V-Notch testing machine, Pendulum Impact Tester Model AI – IT 30. The maximum and minimum UTS noted for the welded joint was 196MPa and 84 MPa for 0.80 KJ/mm and 0.3 KJ/mm heat input respectively. However the Maximum and minimum CVN value noted 26 Jules and 8 Jules for 0.80 KJ/mm and 0.30 KJ/mm respectively. The maximum failures of large structures were observed from the Heat affected zone of welding. The HAZ can be minimizing by selecting the appropriate welding parameters like current, voltage and speed etc. S/N ratio analysis and ANOVA analysis were carried out for finding the optimal level of process parameters and significant effect of process parameters on Quality characteristics respectively. By considering above the study was undertaken by conducting the experimental work for getting defect free, robust and cost saving weld structures.

Keywords: MIG welding, Aluminum Alloy 6061, CVN Test, UTS Test, ANOVA.