Thermal cycle characterization of 6063-T5 aluminium alloy in pipe welding by GMAW process

This study examines the thermal welding cycle of 6063-T5 aluminium alloy pipes joined by Gas Metal Arc Welding (GMAW), emphasizing the influence of welding parameters on cooling behaviour. The main objective is to experimentally characterize the thermal cycle of a transverse pipe weld and optimize conditions to control the cooling time between 400 °C and 300 °C (𝑡4/3), the cooling slope, and the maximum weld temperature. An L9 Taguchi experimental design was implemented using welding power, welding speed, and edge separation as control factors. Thermal cycles were recorded with a thermographic camera and analysed through signal-to-noise ratios and ANOVA. Results show that edge separation has the greatest effect on 𝑡4/3, while welding power mainly influences the cooling slope. No significant correlation was found between welding parameters and peak temperature. An optimal parameter combination was identified, improving thermal cycle control and offering practical guidance for GMAW welding of 6063-T5 aluminium pipes. This work highlights the importance of thermal cycle management in aluminium welding, providing insights for process optimization and structural integrity. The findings contribute to better understanding of heat transfer and cooling kinetics in GMAW, supporting efficient parameter selection for industrial applications.