121- 128


 
  

Al-Khwarizmi 
Engineering   

Journal 
Al-Khwarizmi Engineering Journal,Vol. 12, No. 3, P.P. 121- 128 (2016) 

 

 
Mechanical Properties of MIG Joints for Dissimilar Aluminum Alloys  

(2024-T351 and 6061-T651) 
 

Nawres Jabar Nasser 
Institute of Technology- Baghdad 
Email: nawresjabaar@yahoo.com 

 
(Received 14 September 2014; accepted 12 May 2016) 

 
 
Abstract 
 

The research aims to investigate the effects of GMAW or MIG welding process on the mechanical properties of 
dissimilar aluminum alloys 2024-T351 and AA 6061- T651. A series of experimental techniques have been conducted 
to evaluate mechanical properties of the alloys, by carrying out hardness, tensile and bending tests for welded and un-
welded specimens. 

Metal inert gas (MIG) has been carried out on sheet metal using ER- 4043(AlSi5) as a filler metal and argon as 
shielded gas. The welded joints were tested by X-ray radiography and Faulty pieces were excluded.  

Welding joints without defects are subjected to heat treatment including heating the joints in furnace to 170 °C for 
half an hour then air cooling to relief welding stress. 

Tensile test was implemented for all specimens which prepared in the dimensions according to ASTM 17500 by 
using Testing machine smart series with preload value 100 kN. Vickers hardness test and microstructure examination 
were made, the last test was bending test which implemented on the welded and un welded specimens which machined 
into standard test specimen dimensions.  

Results of mechanical properties Using MIG welding process appear a general decay compared with un welded and 
in the dissimilar joint comparing with parent metal that is due to the microstructure change during the welding process. 
The location of the failure for welded specimens after all mechanical test was found predominantly along the heat 
affected zone ( HAZ ).but Unwedded specimens were failed near the center line of the specimen.   
 
Keywords: Aluminum alloys, welding joining, dissimilar materials welding technologies, mechanical properties. 
 
 
1. Introduction 
 

A wide range of applications for aluminum and 
its alloys are used successfully in industry, from 
Packaging to aerospace. Because it have a good 
mechanical properties and low densities, [1, 2] 
.Heat treatable aluminum alloys (as such 2024 and 
6061) are specially produced for critical 
applications with advanced mechanical properties 
of high strength and ductility. The term of Gas 
metal arc welding means a process that melts and 
joins metals by heating them with an arc arise of 
the base metal and continuously fed filler wire 
electrode. During this processes inert gases are 
used to isolate the weld region from environment 
effects such as argon and helium which are most 

widely used in arc welding process for aluminum 
alloys [3]. Designers and technologists confront 
many difficulties when dealing with the welding 
of aluminum and its alloys. mainly related to the 
presence of a tenacious oxide layer, high thermal 
conductivity, high coefficient of thermal 
expansion, solidification shrinkage and, above all, 
high solubility of hydrogen, and other gases, in 
molten state [4].These difficulties are also arise 
when welding a heat-treatable alloys, since heat, 
provided by welding process, after welding there 
is a decay in mechanical properties, due to phase 
transformations and softening induced in alloy. 
For that aluminum alloys are generally classified 
as low weld ability because of the poor 
solidification microstructure and porosity in the 
fusion zone. 



 Nawres Jabar Nasser                  Al-Khwarizmi Engineering Journal, Vol. 12, No. 3, P.P. 121- 128 (2016)                 

122 
 

Also, the loss of mechanical properties as 
compared to the base material is very significant. 
These factors make the joining of these alloys by 
conventional welding processes unattractive, there 
for there must be fetching for other welding 
processes [5]. 

Therefore in important applications of 
aerospace and similar, those special heat treatable 
alloys are not suitable for conventional welding 
processes but its need to be friction stir welded   
[4][6]. The AA6061-T6 alloys can be welded with 
ER4043 (Al-Si5) or ER5356 (Al-Mg5) filler alloys 
dependent on weld performance requirements. 
The properties of aluminum alloy affect on 
welding process, such as high thermal 
conductivity, high chemical reactivity with 
oxygen, and high hydrogen solubility at high 
temperature. The main consideration is to 
adequately dilute the Mg2Si percentage in the base 
material with sufficient filler alloy to reduce weld 
metal crack sensitivity. 

More attention must be taken when welding 
the 6061-T6 base alloy with the 5356 filler alloys 
to ensure sufficient additions of filler alloy to 
prevent the Al – Mg from crack the sensitivity 
chemistry range [7]. In addition to the base 
material used in this study is 2024-T3 Aluminum 
alloy. It is found that copper (Cu) gives 
substantial increases in strength, allows 
precipitation hardening, reduces corrosion 
resistance, ductility and weld ability. Also in this 
series of aluminum alloys it is difficult to weld by 
liquid state join because many of these series are 
thermal cracking sensitive [8]. 

The present work investigated the mechanical 
behavior  of welded joints of Al2024 and Al6061, 
as well as dissimilar joints between Al 2024T351 
and Al6061T651, using ER4043 filler wire and 
the -GMAW process. 
 
 
2. Experimental Procedure  
 
2.1. Used Alloys 
 

plates of 200 mm long, 100 mm wide and 10 
mm thick of 2024-T351 and 6061-T651 
aluminum alloys which its chemical composition 
analysis by using ARL Spectrometer is given in 
Table (1,2) and its stander mechanical properties 
are shown in Table (3) ,were joined together using 
GMAW process.  

ER4043 was used as a filler metal rod, its 
chemical composition is shown in Table (4).The 
welded butt joints in dimension of (200*100*8) 
mm are produced with the preparation angle in 

shape V of 70⁰  and square angle  as shown in 
Fig.(1).  

These sheets were cleaned before the welding 
process with a scraper and acetone then they were 
butt welded (two pass for each side) by a MIG-
350 type semiautomatic welding machine with 
parameters shown in Table (5).  

S

VI
InputHeat

60
  

××
=

               
   ... (1) [9] 

Where:  
I= welding current (Ampere) 
V= welding voltage (volt) 
S= welding speed (m/min) 
Heat Input= Joule 

 
Table 1, 
Chemical Composition of the used metal AA( 6061 
T651) [10]. 

Elements 
w% 

Measured 
value 

Standard  
value 

Si 0.6 0.4-0.8 
Fe 0.4 Max 0.7 
Cu 0.3 0.15-0.4 
Mn 0.12 Max 0.15 
Mg 1.0 0.8-1.2 
Cr 0.2 0.04-0.35 
Zn 0.18 Max 0.25 
Al Rem. Rem. 
 
Table 2, 
Chemical Composition of the used metal AA 
(2024T351)[10]. 
Elements 
w% 

measured 
value 

Standard  
Value [9] 

Al % 92.6 Rem 
Ti% 0 0-0.15 
Cr% 0.05 0-0.1 
Zn% 0.1 0-0.25 
Si% 0.4 0-0.5 
Fe% 0.3 0-0.5 
Mn% 0.6 0.3-0.9 
Mg% 
Cu% 

1.5 
4.4 

1.2-1.8 
3.8-4.9 

 
Table  3,  
Standard Mechanical Properties of 2024T351 and 
6061T651 [6]. 

Mate
rial 

Yield 
strength  
MPa. 

Ultimate 
tensile 
 strength  
( UTS) 
 MPs. 

Percentage of 
elongation  
% 
 

2024-
T3 

380 464 16 

6061-
T6 

295 342 10 

 



 Nawres Jabar Nasser                  Al-Khwarizmi Engineering Journal, Vol. 12, No. 3, P.P. 121- 128 (2016)                 

123 
 

Table  4, 
Chemical Composition of the Filler Metal (Filer wire ER 4043) Al Si5 [11].

Elements Wt% Actual value Nominal value 
Si 5.0 4.5-6 
Fe 0.4 <0.6 
Cu 0.1 <0.3 
Mn 0.08 < 0.15 
Mg 0.06 < 0.2 
Cr 0.25 - 
Zn 0.15 < 0.1 
Sn 0.15 - 
Al 93.44 Rem. 
 
Table (5)  
Welding Parameters of MIG Welding 
Symbol Current 

(Amp.) 
Voltage 
(v.) 

Travel speed  
     (mm/s) 

Flow rate 
L/min 

No. of 
passes 

Heat input 
(Joule) 

Wire diameter 
(mm) 

C 140 22 220 10 2 456120 1.2 
D 150 22 110 10 2 977400 1.2 
E 160 24 220 10 3 568669 1.2 
F 120 24 120 10 3 130320 1.2 

 
 

 
 

 
 

Fig .1. The Welded Joints Dimension in (mm). 
 
 
2.2. Categorization of Welded Joint 
 

After completing preparation of the specimen, 
they were categorized to groups as shown in 
Table (6). 
 
 
 
 
 
 
 

Table (6)  
Categorizing of Specimens. 
 

 
 
2.3 Microstructure Test 
 

The Changes of micro structural from weld 
zone to the unaffected base material were tested 
using optical microscope. Specimens were 
prepared in many steps for microstructure test 
including wet grinding operation using emery 
paper of different grits (120,320,500, 800 and 
1000). Polishing process was done by using 
diamond paste of size (0.3µm) with special 
polishing cloth. They ere cleaned with alcohol and 
water and then dried with hot air dryer. 
Etching for the structure by use Keller’s reagent 
consisting of 95 ml distill water, 2.5 ml  HNO3, 
1.5 ml HCl and 1 ml HF then  washed  after that 
with ME-600 computerized optical microscope 
provided with a NIKON camera, the examined 
result was shown in Fig.(2). 
 
 

Symbol Condition 
A AA 6061-T651 as received  
B AA 2024-T351 as received 
C Butt Single V AA 6061-T651 at 70° 
D Butt Single V AA 2024-T351 at 70 
E Butt single V dissimilar AA 6061-

T651,2024-T351 at 70° 
F Butt single dissimilar AA 6061-

T651,2024-T351 Square Butt joint (angle 
90°) 



 Nawres Jabar Nasser                  Al-Khwarizmi Engineering Journal, Vol. 12, No. 3, P.P. 121- 128 (2016)                 

124 
 

  
 

   
Specimen (A) 

 
Specimen (B) 

 
Specimen (C) 

 

   
Specimen (D) 

 
Specimen (E) 

 
Specimen (F) 

 
Fig . 2. The Microstructure of (A,B as received and C,D,E,F in weld Zone) (40X).  

           
 
2.4. Mechanical Tests 
 

Before implementing the mechanical tests, 
weld joints were characterized by the visual 
inspection and X-ray radiography. The 
Radiographic unit was operated for 1 min at 150 
kV, 2 mA for the inspection. The joints without 
defects were used to prepare many specimens for 
mechanical test. 
 
2.5. Tensile Test 
 

The dimensions of the tensile specimens were 
prepared according to ASTM (17500) as shown in 
Fig. (3) Multiples of specimens are cut from   
welded and un welded plates with the condition 
that loading axis of the tensile test specimens is 
transverse (perpendicular) to the welding direction 
of the plates.  

Tensile properties were estimated at room 
temperature using the computerized Tinus Olsen 
universal tensile testing machine. All tensile tests 
were carried out at a constant crosshead speed of 
10 mm/min and the average of three specimens 
was taken to evaluate the tensile behavior of each 
welded joint. Fig. (4) shows the test specimens 
after fracture while the test results are shown in 
Table (7) and the relationship between stress and 
strain are shown in Fig. (5) for all specimens. 
 

 
 

Fig. 3. Dimensions of Tensile Test Specimen in mm. 
 

 

 

Fig. 4. Tensile test Fracture  specimens. 

 
50 µm 50 µm 

50 µm 50 µm 50 µm 

50 µm 

Mg2Si 

AlCu 

Mg2Si 



 Nawres Jabar Nasser                  Al-Khwarizmi Engineering Journal, Vol. 12, No. 3, P.P. 121- 128 (2016)                 

125 
 

Table  7, 
Mechanical Tests result. 
Sample σu  

MPa 
Yield stress σy  
MPa 

FB  
kN 

Elongation  % Hardness 
Hv(kg\ ) 

A 270 230 13.42 12 125 
B 323 295 11.25 10 130 

C 159 123 2.48 9 82 

D 165 150 2.18 8 87 

E 200 183 2.81 8 84 

F 170 152 1.19 10 86 

 
 

 
 

Fig. 5. Relationship between stress and strain for all 
specimens. 
 

 
2.6. Bending Test 
 

The dimensions of bending test specimen were 
prepared according to the ASTM (E 190-192) for 
the welded joint as shown in Fig. (6). 

 
Fig. 6. Bending test specimen dimensions in mm. 
 

Face bending tests were carried out at room 
temperature using three point's method Fig. (7). A 
cylinder-shaped line load is applied against the 
weld line, also the center line, of the specimen. As 
the specimen is supported on the sides by a steel 
fixture, it begins to yield because of bending. This 
test was conducted out on a 100-kN universal 
testing machine at a speed of 3.5 mm/min. The 
maximum load registered by the machine during 
bending was used to indicate the strength of the 
weld joint. 

 
 

Fig .7. Bending Setup (Push travel technique). 
 

 

 

 

 
 

Fig. 8. Photos of bending test specimens after 
fracture  

 
 

2.7. Micro Hardness Test 
 

Micro hardness test of the welded joints was 
accomplished using the Vickers hardness tester. 
According to the ASTM, Vickers hardness 
measurements were taken 2 mm below the top 
surface of the specimen perpendicular to the 
welding direction across the weld zone, heat 
affected zone (HAZ) and the base materials using 



 Nawres Jabar Nasser                  Al-Khwarizmi Engineering Journal, Vol. 12, No. 3, P.P. 121- 128 (2016)                 

126 
 

a diamond pyramid indenter with a load of 30 kg 
and loading within 15 sec.  
Tests, results for all specimens are shown in Fig. 
(9). 
 

 
 

Fig. .9. Micro Hardness Result for All Specimens. 
 
 

3. Discussion 
 
    In this work chemical composition and 
mechanical properties have been conducted for 
the material used to check the composition, 
mechanical properties of the Al-alloy type and 
compare it with the standard, as shown in Table 
(1, 2, 3). 

The microstructure of base metal aluminum 
alloy 6061-T651 was shown in Fig. (2) Specimen 
(A) observed coarse and elongated grains with 
uniformly distributed very fine precipitates. The 
presence of alloying elements such as silicon and 
magnesium contribute to the higher strength of the 
base metal. These two elements combined 
together and subjected to precipitation reaction 
and form a strengthening precipitate of Mg2Si. 
Resulting the fine and uniform distribution of 
these precipitates throughout the aluminum matrix 
which give higher strength to these alloys [12] 
and microstructure of base metal aluminum alloy 
2024-T351 in Fig. (2) specimen (B) reveal coarse 
dendritic structure and elongated grains with 
uniformly distributed very fine precipitate and  
from the chemical Composition of alloys which 
referred in table (2)The copper (Cu) is the main 
element in alloy 2024 T351 gives substantial 
increases in strength, permits precipitation 
hardening [13]. The fusion zone of MIG welded 
joints for 6061-T651 and 2024-T351 shown in 
Fig. (2) specimens (C,D) contain dendritic 
structure. The heat input fuses the base metal and 
filler metal to generate a zone with a composition 
that is in different from that of the base metal 
Excess silicon in Composition of wire filler is 

found to be beneficial for increasing the ductility 
of the welded structure.  
The spacing of weld region is wider in MIG joint 
and as result of the increase in welding heat of the 
base metal and fast cooling of molten metal 
Segregation appear.  

The mechanical tested results of all specimens 
in this study was listed in Table (7)   .Include the 
yield strength, UTS and elongation, bending force 
and macro hardness   as compared with that of the 
base metal .Table (3) the alloy 2024-T351 in un 
welding and welding conditions has better 
mechanical properties than the 6061T651 because 
of copper effected which increases in strength. 
These alloys using MIG welding process evidence 
the difference in the microstructure and 
contributes to reduced mechanical properties and 
poor elongation observed during testing. MIG 
welding process required high temperature for 
fusion, the HAZ region was large as well as and 
the subsequent melting and solidification that 
occur, voids are common defects found in fusion 
welds which contributed in that decay . The 
fracture surface section of tensile test specimens is 
shown in figure (4). The location of the failure for 
welded specimens after all mechanical test was 
found mainly along the HAZ region, they had 
failed at the weld metal with sudden fracture 
without reduction in area or necking. But Un 
welded specimens were failed near the center line 
of the specimen.  Bending test results show that 
the bending load was reduced as compared with 
that of the base alloy but did not show any crack 
in the weld joints. The bend test showed Fig.(8) 
that joints welded in all welding conditions were 
very brittle and subjected of very low bend angle 
without cracks ,specimens (C,D ) gives a lower 
bending force comparing with un welded alloys 
that goes with [14, 15, and 16], while bending in 
dissimilar specimens (E,F) has a slightly better 
bending result than similar joints. 

When comparing bending and tensile results of 
sample (E, F) it shows that sample (E) gives better 
results because of the welding angle preparation, 
where V shape angle contributed of heat input 
distribution causing a homogeny in microstructure 
compared to sample (F). 

Table (7) shows the hardness values of the 
specimens, in general it was reduced as compared 
with the base alloy. The minimum hardness value 
was recorded in sample (C),where hardness in  
weld metal area was about (82 HV) and in the 
HAZ was about (100 HV), this value was larger 
than in the weld metal but lower than of the base 
alloy which is about (130HV)Fig. (9), this 
reduction in hardness occurs due to high heat 



 Nawres Jabar Nasser                  Al-Khwarizmi Engineering Journal, Vol. 12, No. 3, P.P. 121- 128 (2016)                 

127 
 

input and grain growth in this region, it can be 
observed that all specimens hardness profile have 
the same hardness distribution in different values. 

 
4. Conclusions  

 
1- Higher heat input in the MIG process has 
reverse effects on the mechanical properties of the 
welded alloys . 
2-The maximum tensile strength of the welded 
joint is (200MPa) compared to (323 MPa)    of the 
base alloy, i.e., the decay of strength about (40%). 
3-Hardness value is affected by the amount of the 
heat input during the welding process. 
4- The base metal has high tensile strength 
compared with the dissimilar materials welding. 
5-It has found that the fracture occurred on the side 
of the aluminum alloy 6061 -T6 compared with 
that of aluminum alloy 2024-T3. 
 
 

5. References 
 
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process parameters on the mechanical 
properties of friction stir welded AA 2014-t6 
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International Journal of Engineering Sciences 
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[2] Benachour M., Hadjoui A., Benguediab 
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[3] Klas Weman ,"Welding Process Handbook", 
Cambridge, England, 2003. 

[4] S. Jannet, P.K. Mathews, R. Raja, 
“Comparative investigation of friction stir 
welding and fusion welding of 6061-T6 and 
5083-O aluminum alloy based on mechanical 
properties and microstructure”, Journal of 
achievements in materials and manufacturing 
engineering, Vol. 6, issue 2, December 2013. 

[5] Marek St. Weglowski, Adam Pietras, 
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parameters on mechanical and microstructural 
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friction stir welding”, Journal of Kones 
Powertrain and Transport, Vol. 16, No. 1, 
2009. 

[6] Nazar abdulwadood1, Burak Sahin1, Nihat 
yildirim” effect of welding parameters on the 
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alloys 2024-t3 to 6061-t6 joints produced by 
friction stir welding” Niğde Üniversitesi 

Mühendislik Bilimleri Dergisi, Cilt 3, Sayı 1, 
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[7] Aendraa Azhar Abdul Aziz ,”Effects of 
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[8] Mustafa Kemal Kulekci,” Experimental 
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[9] Jatinder Gill, JagdevSingh, “Effect of Welding 
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[10] Metals Handbook, Vol.2 - Properties and 
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[11] Annual Book of ASTM Standards, Standard 
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[12] T Senthil Kumar, V Balasubramanian, M Y 
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[13] M R Ahmad, M A Bakar, “Effect of post-
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[14] P. Cavaliere, R. Nobile, F. W. Panella andA. 
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[15] Muafaq Mehdi Salih, "Studying the effect of 
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[16] S. Missori and A. Sili, "Mechanical behavior 
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18, 2000, pp.12-18. 



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