Evaluation on the Mechanical Strength of TIG Welded 6061Aluminium Alloy Joints

Year : 2026 | Volume : 13 | Issue : 01 | Page : 34 39
    By

    Prashanth Pai M.,

  • Manujesh B.J.,

  • Mohammed Saleem,

  • Amil Azeez,

  • Nithin M.K.,

  • C.V. Pujar,

  1. Student, P.A. College of Engineering, Mangalore, Karnataka, India
  2. Professor, VCET, Nehru Nagar, Karnataka, India
  3. Student, P.A. College of Engineering, Mangalore, Karnataka, India
  4. Student, P.A. College of Engineering, Mangalore, Karnataka, India
  5. Student, P.A. College of Engineering, Mangalore, Karnataka, India
  6. Student, P.A. College of Engineering, Mangalore, Karnataka, India

Abstract

Aluminum alloy Al-6061 is extensively used in aerospace, automotive, and marine industries due to its excellent mechanical properties, lightweight nature, and corrosion resistance. However, welding this alloy presents challenges such as porosity, hot cracking, and strength reduction in the heat-affected zone (HAZ). Tungsten Inert Gas (TIG) welding, known for its precision and quality, is commonly employed for joining Al-6061. This study investigates the tensile strength of TIG-welded butt joints of Al-6061 alloy, focusing on the influence of key welding parameters. Tensile tests were conducted on welded samples to evaluate their mechanical performance. The results demonstrate the relationship between process parameters and joint strength, providing valuable insights for optimizing TIG welding conditions to achieve stronger and more reliable welds. In addition, the study examines the effects of welding current, travel speed, shielding gas flow rate, and filler material selection on weld quality and tensile behavior. Standardized specimen preparation and testing procedures were adopted to ensure repeatability and accuracy of the results. Fracture characteristics of the tensile- tested specimens were also analyzed to identify the predominant failure locations, particularly within the weld metal or the HAZ. The findings reveal that appropriate control of TIG welding parameters significantly improves joint efficiency and minimizes common welding defects. The outcomes of this work contribute to a better understanding of TIG welding behavior in Al-6061 alloy and serve as a practical guideline for industrial applications requiring high-strength and defect-free aluminum welds.

Keywords: Al 6061; TIG welding; Tensile Strength, HAZ; Porosity; Hot cracking

[This article belongs to Trends in Machine design ]

How to cite this article:
Prashanth Pai M., Manujesh B.J., Mohammed Saleem, Amil Azeez, Nithin M.K., C.V. Pujar. Evaluation on the Mechanical Strength of TIG Welded 6061Aluminium Alloy Joints. Trends in Machine design. 2026; 13(01):34-39.
How to cite this URL:
Prashanth Pai M., Manujesh B.J., Mohammed Saleem, Amil Azeez, Nithin M.K., C.V. Pujar. Evaluation on the Mechanical Strength of TIG Welded 6061Aluminium Alloy Joints. Trends in Machine design. 2026; 13(01):34-39. Available from: https://journals.stmjournals.com/tmd/article=2026/view=241973


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Regular Issue Subscription Original Research
Volume 13
Issue 01
Received 03/02/2026
Accepted 09/02/2026
Published 25/02/2026
Publication Time 22 Days
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