A comprehensive review on the effect of TIG welding parameters on intermetallic formation and mechanical properties of dissimilar aluminum alloy welds

• Intermetallic compounds (IMCs) formation reported on varying Tungsten Inert Gas (TIG) welding parameters • Mechanical properties of dissimilar aluminum alloy joints observed after TIG welding • Optimized welding parameters minimize the formation of brittle IMCs • Refine grain structures, and enhance the mechanical integrity in the weld zone. • TIG supports sustainable and efficient manufacturing practices for dissimilar aluminum alloy joints. The production of intermetallic compounds (IMCs) and the mechanical characteristics of different aluminum alloy joints are examined in this review in relation to Tungsten Inert Gas (TIG) welding conditions. The study emphasizes how crucial welding current, filler material composition, shielding gas flow, and welding speed are in regulating the welded joints' microstructure, hardness, and tensile strength. Optimized welding parameters reduce the production of brittle IMCs, improve the mechanical integrity of the weld zone, and refine grain architectures, according to microstructural analysis. Additionally, the review highlights the improved performance of modern TIG variants including modern Active-TIG (AA-TIG) and Activated-TIG (A-TIG), which increase joint strength and weld penetration while lowering heat input. Environmental factors were taken into account, demonstrating how energy-efficient setups and sustainable welding techniques may lower emissions and resource usage. The results of this study offer a thorough understanding of how adjusting TIG welding parameters supports sustainable and effective manufacturing procedures for dissimilar aluminum alloy joints in addition to improving weld quality and mechanical qualities.