| METALS AND METAL MATRIX COMPOSITES |
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| Effects of High-frequency Duty Cycle on Weld Formation, Microstructure, and Mechanical Properties of 6082 Aluminum Alloy Joints Produced by Double-pulse MIG Welding |
| WANG Weihan, SHAO Jiaxu, GU Xiaoyan*
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| Key Laboratory of Automobile Materials, Ministry of Education, College of Materials Science and Engineering, Jilin University, Changchun 130022, China |
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Abstract This study systematically investigated the effects of the high-frequency duty cycle on weld formation, microstructure, and mechanical properties of 6082 aluminum alloy joints produced by double-pulsed metal inert gas (DP-MIG) welding.The high-frequency duty cycle was varied from 10% to 40%, while all other welding parameters were kept constant.Synchronized high-speed imaging and electrical signal acquisition were employed to analyze droplet transfer dynamics and arc behavior in real time.The results showed that decreasing the high-frequency duty cycle shortened the duration of the high-energy pulse stage, reduced the average heat input, and weakened Marangoni convection.Consequently, weld-pool fluctuations became less pronounced, the characteristic fish-scale ripples gradually faded, and the weld penetration slightly decreased.The average grain size in the weld metal decreased from 13.50 μm at a duty cycle of 40% to 11.65 μm at 10%, indicating that the lower heat input suppressed grain growth by shortening the high-temperature residence time and increasing the cooling rate.As a result, the longitudinal tensile strength increased significantly, whereas the transverse tensile strength changed only slightly, suggesting that the differences in heat input were insufficient to markedly alter the degree of softening in the heat-affected zone.
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Published: 25 July 2026
Online: 2026-08-12
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