Comparative Analysis of Mechanical Properties and Microstructural Evolution in TIG, MIG, and FSW Weldments of AA5052 and AA6082 Aluminum Alloys

Hyginus Chidiebere Onyekachi Unegbu; Danjuma S. YAWAS; Bashar Dan-asabe; Abdulmumin Akoredeley Alabi

Hyginus Chidiebere Onyekachi Unegbu
Department of Mechanical Engineering Ahmadu Bello University Nigeria
Danjuma S. YAWAS
Department of Mechanical Engineering Ahmadu Bello University Nigeria
Bashar Dan-asabe
Department of Mechanical Engineering Ahmadu Bello University Nigeria
Abdulmumin Akoredeley Alabi
Department of Mechanical Engineering Ahmadu Bello University Nigeria

Keywords Energy-Efficient Technologies, Sustainable Construction, Nigeria, Regulatory Support, Stakeholder Awareness, Financial Barriers, Environmental Sustainability

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Abstract

This study comprehensively evaluates the mechanical properties and microstructural characteristics of AA5052 and AA6082 aluminum alloys joined using three different welding techniques: Friction Stir Welding (FSW), Tungsten Inert Gas (TIG), and Metal Inert Gas (MIG) welding. The primary objective was to determine the most effective welding technique for optimizing the mechanical strength, ductility, hardness, and impact resistance of these commonly used aluminum alloys. Extensive mechanical testing revealed that FSW weldments exhibited superior ultimate tensile strength (UTS), higher elongation at break, and greater impact energy absorption compared to TIG and MIG weldments. Microstructural analysis, utilizing optical microscopy, SEM, EDS, and XRD, demonstrated that FSW produced a fine-grained, homogeneous microstructure with a uniform distribution of precipitates, contributing to its enhanced mechanical properties. In contrast, TIG and MIG welding resulted in coarser grain structures, pronounced heat-affected zones (HAZ), and uneven precipitate distribution, leading to reduced mechanical performance. The study concludes that FSW is the preferred welding technique for critical applications requiring high structural integrity and performance, offering valuable insights for industries that rely on advanced aluminum alloy weldments.

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