Abstract
The article reviews the difficulties and its redressal in fusion welding (especially the most used welding processes in the industry; gas metal arc (GMA) and gas tungsten arc (GTA) welding) of aluminium alloys. The more excellent thermal conductivity, solidification shrinkage, oxide formation, and thermal expansion coefficient cause more difficulties welding aluminium alloy than other materials. Welding parameters (such as welding current, welding voltage, shield gas flow rate, welding speed, torch location, etc.) have a complicated and non-linear relationship with the weld's quality and the joint's mechanical characteristics. Several techniques are suggested for improved weld quality and joint strength, including pulsing the current, post-weld heat treatment, proportional mixing of the shielding gases, speedy shielding gas injection, and many more. Due to various materials varied chemical and thermal characteristics, the GMA and GTA welding of dissimilar aluminium alloy exhibits more difficulties. To get around the challenges, adjusting the torch position and choosing a filler material that works with both aluminium alloys are practiced.