Optimization of electron beam welding parameters to improve corrosion resistance of AA2219 aluminium alloy

B Rajnaveen; D Balaji Naik; G Rambabu; K Srinivasa Rao

Authors

B Rajnaveen Department of Mechanical Engineering, Andhra University, Visakhapatnam, India-530003
D Balaji Naik Department of Mechanical Engineering, Universal College of Eng. & Tech, Guntur India-52200
G Rambabu Department of Mechanical Engineering, Andhra University, Visakhapatnam, India-530003
K Srinivasa Rao Department of Mechanical Engineering, Andhra University, Visakhapatnam, India-530003

Keywords:

AA2219 alloy, corrosion resistance, electron beam welding, response surface methodology, travel speed, voltage, welding current

Abstract

Aluminium alloys are ideal for the production of lightweight structures. These alloys also have a high strength-to-weight ratio and superior corrosion resistance. Electron beam welding (EBW) is widely used for the joining of AA2219 al alloy, which is a high-energy beam welding technology that melts the workpiece surface and forms the joint using a focused beam of electrons. The Taguchi method of experimental design was applied in this study to examine the effect of input parameters on corrosion resistance. Input parameters like welding current, travel speed and voltage are used as controlling parameters to create the experimental design, and each parameter is divided into three levels. Therefore, an L9 orthogonal array was used for the experimental design. Potentio dynamic polarization tests were conducted for all designed experimental arrays to determine the pitting potential (corrosion resistance) in millivolts. An Analysis of Variance (ANOVA) technique was used to determine the governing parameters of the process. The findings of ANOVA revealed that voltage is the most influential parameter, followed by welding current and travel speed. Further, response surface methodology (RSM) has been used to form the mathematical model of the AA2219 aluminium alloy. This mathematical model helped in finding the predicted value of pitting potential. The optimized parameters of the AA2219 aluminium alloy were obtained by using RSM. The outcomes of RSM indicate that maximum corrosion resistance is achieved when welding current, travel speed and voltage are chosen as 50 mA, 1200 mm/min and 53 kV respectively.

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