Guo Wei, Zhao Xincheng, Zhao Yonglin, Liu Yuxiang, Li Han, Han Bingyuan
School of Mechanical Engineering, Nantong University, Jiangsu Nantong, 226019, China.
School of Automotive and Traffic Engineering, Jiangsu University of Technology, Chang Zhou, 213001, China.
Sci Rep. 2025 May 4;15(1):15593. doi: 10.1038/s41598-025-99836-6.
Heat input represents a critical process parameter that significantly influences the quality of tungsten inert gas (TIG) welding. In this study, a comprehensive investigation of heat input effects on the welding quality of thin-gauge aluminum alloy was conducted through integrated theoretical analysis and experimental validation. The research established an optimal heat input range of 296-321 J/mm for 3 mm thick 5083 aluminum alloy plates in TIG welding applications, within which welded joints demonstrated minimal defect formation and superior mechanical performance. Both numerical simulations and experimental results revealed a distinct non-monotonic relationship between heat input and joint properties: when operating below the optimal range, progressive increases in heat input resulted in corresponding improvements in fusion characteristics and mechanical properties. Conversely, exceeding the optimal range led to progressive grain coarsening within the weld microstructure, accompanied by measurable degradation in key mechanical properties including tensile strength and hardness.
热输入是一个关键的工艺参数，对钨极惰性气体保护焊（TIG）的焊接质量有重大影响。在本研究中，通过综合理论分析和实验验证，对热输入对薄规格铝合金焊接质量的影响进行了全面调查。研究确定了在TIG焊接应用中，3毫米厚5083铝合金板材的最佳热输入范围为296 - 321焦耳/毫米，在此范围内，焊接接头的缺陷形成最少，机械性能优异。数值模拟和实验结果均表明，热输入与接头性能之间存在明显的非单调关系：当热输入低于最佳范围时，热输入的逐步增加会相应改善熔合特性和机械性能。相反，超过最佳范围会导致焊缝微观结构中的晶粒逐渐粗化，同时关键机械性能（包括抗拉强度和硬度）会出现明显下降。
