Automation of Aluminum Alloy Welding

P. Kah(1*)

(*) Corresponding author

Authors' affiliations

DOI's assignment:
the author of the article can submit here a request for assignment of a DOI number to this resource!
Cost of the service: euros 10,00 (for a DOI)


Aluminum and its alloys, due to the characteristic features of aluminum like low density, good strength, ductility, corrosion resistance, and high thermal and electrical conductivities, are being used in a wide number of industrial applications, and the welding processes for aluminum are being automated for high-scale manufacturing. However there are some difficulties associated with the welding of aluminum for different welding processes. This work aims to describe and compare various methods for the automated fusion welding processes of aluminum alloys. It is almost exclusively made by reviewing several research articles and literature and discusses about the fusion welding process for aluminum alloys, its benefits, drawbacks, and usual applications. The most usual defects generated by these processes are also the target of this analysis. Two comparison tables are also presented and commented on, one comparing the features of each type of welding process and the other on comparing quantitative parameters, like the welding speed and weld type, as well as the quality of the weld, from various real world applications. It was found that the automated welding of aluminum is a well-established subject and that solutions for most industrial automated aluminum welding needs can be further explored
Copyright © 2014 Praise Worthy Prize - All rights reserved.


Aluminum; Automation; Sensor; Hybrid Laser Arc Welding

Full Text:



E. Craig, The plasma arc process - a review, Welding Journal, Vol. 2, pp. 19-25, 1988.

W. Tuttle, Understanding aluminum welding, Welding Journal, Vol. 70, pp. 43-46, 1991.

P. F. Mendez and T. W. Eagar, Welding processes for aeronautics, Advanced materials and processes, Vol. 159, n. 5, pp. 39-43, 2001.

G. Mathers, Welding of Aluminium and Its Alloys, Woodhead Publishing, 2002.

Lindon Robert Lee, C., Neilash Kumar, P., Antony Raja, S., Ravichandran, K., Gopala Krishnan, G., Characterization of Al 6061 alloy using pulsed gas tungsten arc welding, (2011) International Review of Mechanical Engineering (IREME), 5 (3), pp. 387-389.

Majumder, A., A comparative study of the ANN with RSM for predicting bead geometry of gas tungsten arc welded AA7039 aluminium alloy joints, (2010) International Review of Mechanical Engineering (IREME), 4 (7), pp. 833-839.

H. Y. Shen, J. Wu, T. lin and S.B. Chen, Arc welding robot system with seam tracking and weld pool control based onpassive vision, International Journal of Advanced Manufacturing Technology, Vol. 39, n. 7-8, pp. 669-678, 2008.

T. Pfeifer and J. Rykała, Robotic welding of thin-walled aluminium alloy elements using low-energy welding methods, Welding International, Vol. 27, n. 7, pp. 497-502, 2013.

R. V. Blewett, Welding aluminium and its alloys - A revie of application and requirements, Welding & Metal Fabrication, Vol. 455, October, p. 449, 1991.

G. Lipnevicius, Robotic TIG Welding - A maintenance option for repeatable, uniform welds, Aircraft Maintenance Technology, July, pp. 16-19, 2010.

J. Hoffman, The Challenges of Robotic Aluminium gas metal arc welding, Welding Magazine, Vol. 80, n. 7, July, pp. 30-32, 2007.

H. Tong, T. Ueyama, S. Harada and M. Ushio, Sci. Technol. Weld. Joining, Vol. 6, n. 4, pp. 203-208, 2001.

H. Tong, Study on the mechanism of fume formation in pulsed MIG welding of Al-Mg alloy, MEng thesis, Welding Research Institute, Osaka University, 1995.

H. Tong, T. Ueyama, K. Nakata and M. Ushio, High speed welding of aluminium alloy sheets using laser assisted alternating current pulsed metal inert gas process, Science and Technology of Welding a nd Joining, Vol. 8, n. 3, pp. 229-234, 2003.

Pulsed MIG may solve aluminum fabrication problems - Q&A, Miller, [Online]. Available: [Accessed 31 August 2013].

J. Mortiner, Jaguar uses adaptive MIG welding to join C-pillars to and aluminium roof section in a new sports car, Sensor Review Vol. 4, n. 26, pp. 272-276, 2006.

T. Matsumoto and S. Sasabe, Tandem MIG welding of aluminium alloys, Welding International, Vol. 19, n. 12, p. 945-949, 2005.

Wolf Robotics, Tandem Wire MIG Welding - Heavy deposition welding at increased welding speed, 2005.

J. Berge, Using the tandem welding process to your advantage,, 24 April 2002.

B. Mannion and J. Heinzman, Plasma arc welding brings better control, Tooling & Production, Vol. 5, n. 65, pp. 29-30, 1999.

B. Zheng, The discontinuous pilot power source for AC PAW, China Weld, Vol. 6, pp. 1-6, 1995.

B. Zheng, Q. L. Wang and R. Kovacevic, Arc interference and a unique push-pull-arc solution in AC PAW of aluminum alloys, J. Engng Mf., 1999.

H. D. Steffens, Automatic control for plasma arc welding with constant keyhole, Welding Journal, Vol. 6, pp. 40-45, 1972.

H. D. Steffens, Automatic control for plasma arc welding with constant keyhole, Welding Journal, Vol. 6, pp. 40-45, 1972.

I. D. Harris, Plasma-MIG Welding, In ASM Handbook - Welding, Brazing and Soldering, Vol. 6, 1993.

N. Makarenko and V. A. Nevidomskij, Thermal cycles im plasma-MIG surfacig, Automatic Welding, Vol. 1, n. 1, pp. 45-47, 2003.

B. Yan, G. Hong-Ming, W. Lin, M. Zhao-hui and C. Neng, Influence of plasma-MIG welding parameters on aluminum weld porosity by orthogonal test, Transactions of Nonferrous Metals Society of China, Vol. 20, pp. 1392-1396, 2010.

A. Schevers, Plasma-MIG welding of aluminum - Increased welding speed and better weld metal quality, Welding and Metal Fabrication, Vol. 44, n. 1, pp. 17-20, 1976.

D. J. C. Oliveira M A, Electrical mode for the plasma-MIG hybrid welding process, Welding and Cutting, Vol. 6, n. 6, pp. 324-328, 2007.

Z. Yi-shun, D. Xiao-qiang and L. De-yuan, Numerical simulation of fluid field and temperature field in plasma torch, Transactions of the China Welding Institution, Vol. 26, n. 9, pp. 77-80, 2005.

K. Ono, Z. Liu, T. Era, T. Uezono, T. Ueyama, M. Tanaka and K. Nakata, Development of a plasma MIG welding system for aluminium, Welding International, Vol. 23, n. 11, pp. 501, 2009.

S. Asai, T. Ogawa, Y. Ishizaki, T. Minemura, H. Minami and S. Iyazaki, Application of plasma MIG hybrid welding to dissimilar joints between copper and steel, Welding in the world, Vol. 56, n. 1-2, pp. 37-42, 2012.

C. A. Huntington and T. W. EAGAR, Laser Welding of Aluminum and Aluminum Alloys, Welding Research Supplement, pp. 105-s - 107-s, 1983.

M. A. Bramson, Infrared radiation: A Handbook for applications, New York, Plenum Press, 1968.

W. W. Duley, Laser Processing and Analysis of Materials, New York, Plenum Press, p. 71, 1983.

M. Pastor, R. P. M. H Zhao and T. Debroy, Porosity, Underfill and Magnesium Loss during Continuous Wave Nd:YAG Laser Welding of Thin Plates of Aluminum Alloys 5182 and 5754, Welding Research Supplement, pp. 207-s - 216-s, June 1999.

C.-H. Kim and D.-C. Ahn, Coaxial monitoring of keyhole d uring Yb-YAG laser welding, Optics & Laser Technology, Vol. 44, pp. 1874-1880, 2012.

J. Weston, J. W. Yoon and E. R. Wallach, Laser welding of aluminium alloys using different laser sources, 6th International Conference on Welding and Melting by Electron and Laser Beams, Toulon, 1998, pp. 15-19.

A. Ascari, A. Fortunato and G. C. Leonardo Orazi, The inflience of process parameters on porosity formation in hybrid LASER-GMA welding of AA6082 aluminum alloy, Optics & Laser Technology, Vol. 44, pp. 1485-1490, 2012.

H. Mayer, F. Venier and K. Koglin, Die ASF-Karosserie des Audi A8, Motortechnische Zeitschrift, Vol. 63, pp. 94-100, 2002.

H. Staufer, Laser hybrid welding and laser brazing: state of t he art in technology and practice by examples of the Audi A8 and VW Phaeton, Proceedings of the 3rd international WLT conference on lasers in manufacturing, 2005, pp. 203-208.

K. Fukami and K. Setoda, Development of high-efficiency MIG-laser hybrid welding technology, Welding International, Vol. 27, n. 2, pp. 87-92, 2013.

KUKA Systems, "KS Hybridtec," Kuka, [Online]. Available: http://www.kuka [Accessed 6 Febraury 2013].

TWI Ltd., "FAQ: What is tandem MIG/MAG (GMA) welding?," TWI, [Online]. Available: [Accessed 25 September 2013].

Lincoln Electric, "Tandem MIG Process," Lincoln Electric, [Online]. Available: [Accessed 28 September 2013].

RobotWorx, "Plasma welding," [Online]. Available: http://www. [Accessed 20 September 2013].

M. M. Andersen and T. A. Jensen, Hybrid NG-YAG Laser + MIG welding in aluminium, FORCE Institute, Broendby, Denmark.

Y.-B. Chen, Y. G. Miao, L. Q. Li and L. Wu, Joint performance of laser-TIG double-side welded 5A06 aluminum alloy, Transactions of Nonferrous Metals Society of China, Vol. 19, pp. 26-31, 2009.


  • There are currently no refbacks.

Please send any question about this web site to
Copyright © 2005-2024 Praise Worthy Prize