Optimising the quality of several welds in a metal-inert gas arc joining of AA6082 and AA7075 using the grey-based Taguchi technique Vinay Kumar, Vipin, RS Mishra Proceedings of the Institution of Mechanical Engineers Part E Journal of Process Mechanical Engineering, 2024 In recent times, welding procedures have become increasingly crucial for fabrication and manufacturing businesses. Gas metal arc welding, also known as metal inert gas (MIG) welding, has attracted much attention because of its versatility. Its benefits include low capital needs, high deposition rates, high productivity, and simplicity in adjusting to automation. It has drawn much interest because of its versatility in welding metallic materials and ease of automation. This work's objective is to maximise the multi-performance properties of the aluminium alloys AA6082 and AA7075's MIG-welded butt junction by using a hybrid grey-based Taguchi technique. During MIG welding, With the L9 Taguchi orthogonal array, the welding speed, gas flow rate, and current were optimised. Weld joint integrity has been evaluated using the fusion zone's Vickers microhardness, per cent elongation, tensile strength, and yield strength. The ideal welding current for the MIG process is 140 A, the perfect welding speed is 10 mm/min, and the excellent gas flow rate is 18 lit/min. The material showed 159.68 MPa of tensile strength, 112.79 MPa of yield strength, 16.79% of percentage elongation, and 70.95 HV of hardness under optimal conditions. With a 63.99% contribution to the process, welding speed greatly affected the weldments' overall performance. The confirmatory test confirmed the optimisation procedure also demonstrated that optimising numerous welded joint performance factors may be achieved effectively with the grey-based Taguchi approach.
Effect of multipass friction stir processing on microstructure and mechanical properties of MIG welded joints of AA6082 and AA7075 Vinay Kumar, Vipin, R. S. Mishra Journal of Adhesion Science and Technology, 2024 Metal inert gas (MIG) welding is widely employed for aluminum alloy welding, but high residual stress, coarse grain's structure, porosity, and micro-cracks occur during MIG welding. To avoid these defects, friction stir processing (FSP) was employed to the MIG welded joints of AA7075 and AA6082 with ER4043 filler. The grain structure of the weld fusion zone (WFZ) was categorized by eutectic precipitated Mg2Si, and primary α-Al. The elongated, coarse grain structure of the MIG weldment decreased after a one pass FSP. The Mg2Si precipitates were disseminated due to the enhancement of dispersion and dissimilar metal fraternization. The fraction area of the refined grains increases when the FSP pass increases. Furthermore, the effective enhancement of the joint efficiency was observed in the MIG + 4Pass FSP due to the grain refinement. The ultimate tensile strength (UTS) of 169.73 MPa of the MIG welded joint was observed with a grain size of 17.9 ± 0.3, while the highest UTS of 223.84 MPa was perceived at 4 passes of MIG + FSP joints with an elongation of 12.45%. The grain structure was also refined as the FSP pass increased, and the minimum grain size (2.6 ± 0.3 µm) was perceived at MIG + 4Pass FSP. Multipass FSP leads to refinement and homogenization of the microstructure, increasing the microhardness of the weldment. The average hardness value of the MIG weldments at the WFZ was 84 HV, while the microhardness of MIG + FSP joints of 1Pass, 2Pass, 3Pass, and 4Pass FSP was 88, 96, 101, and 110 HV at the stir zone (SZ).
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MOST CITED SCHOLAR PUBLICATIONS
Numerical and experimental investigation of hole flangeability of AA6061 alloy V Kumar, DR Kumar IOP Conference Series: Materials Science and Engineering 1284 (1), 012018 , 2023 2023 Citations: 6
Stretch flangeability of aluminum alloys: a key to advancing lightweight design V Kumar, D Ravi Kumar Journal of Materials Engineering and Performance 35, 3567-3580 , 2025 2025 Citations: 3
Influence of hole preparation technique on stretch flangeability of aluminium alloys V Kumar, DR Kumar IOP Conference Series: Materials Science and Engineering 1307 (1), 012044 , 2024 2024 Citations: 3
Formability analysis of aluminium alloys in circular and square hole flanging for lightweight manufacturing V Kumar, RK Digavalli The International Journal of Advanced Manufacturing Technology 142 (1), 899-912 , 2025 2025 Citations: 1
Numerical Prediction of Stretch Flangeability of DP600 Steel Sheets Using Different Material Models V Kumar, A Shrivastava, DR Kumar Transactions of the Indian Institute of Metals 79 (6), 96 , 2026 2026
