Modeling and Analysis of Mig Welded Aluminum Alloy and Brazed Galvanized Steel Joint

This research focuses on the modeling and analysis of metal inert gas welded aluminum alloy and galvanized steel joints using ESI SYSWELD, with an emphasis on evaluating structural stress and thermal behaviour. The materials considered in this study are Aluminum Alloy 6061-T6 and EN10130 DC-04 galvanized steel, widely used in engineering applications. The joint is developed using ER4043 filler wire, selected for its favorable silicon content, which enhances weldability, improves fluid flow, and minimizes hot crack formation in AA6061-T6. The lap joint configuration is modelled and analyzed to compare its performance. The findings of the research are based on simulation results presented in graphs showing structural stress distribution and thermal behaviour. The analysis highlights variations in deformation and temperature distribution between the joint types under different conditions. It is observed that the lap joint provides better performance compared to the butt joint due to the improved bonding area and reduced risk of brittle failure. Critical regions of stress and thermal gradients are identified for both configurations. Overall, the study concludes that The ER4043 filler wire and lap-joint configuration are best suited for joining AA6061-T6 aluminum alloy and EN10130 DC04 steel, and the results are useful for improving joint design in automotive and aerospace applications.