Experimental investigation and numerical analyses of residual stresses and distortions in GMA welding of thin dissimilar AA5052-AA6061 plates

An experimental investigation involving gas metal arc welding is carried here to determine the temperature distribution, longitudinal and transverse residual stresses and distortions in joining two thin dissimilar aluminium alloys AA5052 and AA6061 plates. The results are validated against numerical simulations using finite element analysis software ANSYS. Three dimensional thermo-mechanical finite element model was used to determine transient temperature, residual stress and distortions. Heat dissipation due to conduction, convection and radiation was considered. The weld samples were tested using X-ray diffraction machine and coordinate measuring machine for measurement residual stress and distortions. Comparison results show good conformity between experimental and numerical results and that AA6061 plate has higher longitudinal and transverse residual stresses and lesser shrinkage than AA5052 plate.