Influence of travel speed on porosity and liquation cracking in cold wire pulsed gas metal arc welding of aa7075-t651 aluminum alloy

This study investigates the impact of travel speed on the weld quality of AA7075-T651 aluminum alloy using the cold wire pulsed gas metal arc welding (CW-PGMAW) process. By maintaining a constant heat input of 0.4 kJ/mm while varying travel speed between 90 and 100 cm/min, the study examines the process’s influence on microstructure, porosity, and liquation cracking. Results demonstrate that CW-PGMAW effectively refines microstructure and reduces defect formation compared to conventional GMAW. While mechanical properties showed improvement, further optimization is necessary to achieve base metal equivalent properties. The findings contribute to the understanding of CW-PGMAW for challenging aluminum alloys and provide a foundation for future process enhancements. Graphical Abstract