Journal of Materials Processing Tech.

266 (2019) 255–263

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Journal of Materials Processing Tech.

journal homepage: www.elsevier.com/locate/jmatprotec

Process characteristics and properties of AA2219 aluminum alloy welded by T

double pulsed VPTIG welding
Yipeng Wanga, Baoqiang Conga,b, , Bojin Qia, , Mingxuan Yanga, Sanbao Linb
⁎ ⁎

a
School of Mechanical Engineering and Automation, Beihang University, Beijing, 100191, China
b
State Key Lab of Advanced Welding and Joining, Harbin Institute of Technology, Harbin, 150001, China

ARTICLE INFO ABSTRACT

Associate Editor: C.H. Caceres A double pulsed variable polarity tungsten inert gas (DP-VPTIG) welding process was employed in the welding
Keywords: fabrication of AA2219 plates. The arc profile was imaged by a high-speed camera based vision sensing system,
Aluminum alloy and the weld pool appearance was captured by a CCD-based area-array camera. The microstructure, micro
Double pulsed hardness and tensile properties of the welded joints were investigated. Results indicated that the arc length L,
Tungsten inert gas welding diameter DB at arc workspace end and diameter DE at arc electrode end fluctuated periodically with the low-
Welding arc frequency pulse. In low-frequency pulse peak stage, the weld pool width Dw increased monotonously, accom-
Weld pool panied by a significant depressed deformation on the weld pool surface. In low-frequency pulse base stage, Dw
continuously decreased with the disappearance of the depressed deformation. Compared with the conventional
VPTIG, the weld zone grain structure of DP-VPTIG was significantly refined, and the micro hardness and tensile
properties of DP-VPTIG welded joints were improved.

1. Introduction content of mixed gases needs to be precisely controlled, which increases

Variable polarity tungsten inert gas welding (VPTIG) is widely used
in aluminum alloys welding owing to its stable welding process as well
as cathode cleaning effect as stated by Pan et al. (2016). The welding
production efficiency of VPTIG is relatively low because of its free di-
verging arc with low energy density. Limited by the current carrying
capacity of the tungsten electrode, the welding current of VPTIG is
usually no more than 250/−250 A. When the current is further in-
creased, the electrode will be easily burnt due to the excessive tem-
perature, which could cause welding defects such as tungsten inclusions
and oxidation of the weld zone. The high heat input could also lead to
severe growth of grain structure in the weld zone, and reduce the
quality of the welded joints as revealed by Wang et al. (2017a).
To improve the production efficiency of TIG welding, a large
amount of measures have been proposed. External magnetic field has
been introduced in arc zone, and it is proved to be beneficial to enhance
the welding speed and weld depth/width ratio as demonstrated by
Nomula et al. (2009). This method requires auxiliary device to generate
magnetic field around the welding torch, making it difficult to realize
automatic TIG welding. Lu et al. (2013) indicated that the mixed
shielding gas TIG welding with mixtures of He, H2, CO2 or O2 is an
effective method to increase the arc energy and weld penetration depth
compared with the conventional TIG welding. In this process, the
the equipment costs. Keyhole TIG (K-TIG) welding was proposed to
improve the welding efficiency through high current value, in most
cases in the range from 300 to 1000 A as reported by Lathabai et al.
(2001). It requires a specially designed welding torch to cool down the
high temperature of the electrode caused by the high current value.
Additionally, this process is mainly applicable to low thermal con-
ductivity materials such as stainless steel, zirconium, titanium alloys,
etc. Vora and Badheka (2015), Cai et al. (2016) and Tseng and Hsu
(2011) showed that activated TIG (A-TIG) welding, a process in which
the surface of parent metal is smeared by an activating flux (halides or
oxides) before welding, could obviously increase the joint penetration
and weld depth/width ratio. FB-TIG (Flux Bounded TIG) and FZ-TIG
(Flux Zone TIG) referred as variants of A-TIG, applying the activating
flux in different regions of the weld, are found useful to simultaneously
increase the weld penetration and obtain perfect weld surface appear-
ance as investigated by Huang et al. (2012). The disadvantages of A-TIG
welding is that it needs a process to manually apply the activating flux
on the weld, which not only takes time but also directly affects the
uniformity and precision, especially in some complex structures.
The current waveform regulation inside the welding power source is
considered to be one of the most effective and flexible ways for welding
process control. High-frequency pulse current, typically more than
20 kHz, has been adopted in TIG welding process. It has been proved

⁎
Corresponding authors at: School of Mechanical Engineering and Automation, Beihang University, Beijing, 100191, China.
E-mail addresses: congbq@buaa.edu.cn (B. Cong), qbj@buaa.edu.cn (B. Qi).

https://doi.org/10.1016/j.jmatprotec.2018.11.015
Received 14 August 2018; Received in revised form 8 November 2018; Accepted 10 November 2018
Available online 12 November 2018
0924-0136/ © 2018 Elsevier B.V. All rights reserved.
Y. Wang et al. Journal of Materials Processing Tech. 266 (2019) 255–263

Table 1 Table 2
Chemical composition of AA2219 and ER2319 (mass fraction/%). Welding current parameters in the tests.
Alloys Cu Mn Ti Zr Fe Si Al Test No. Parameter

AA2219 6.58 0.3 0.1 0.2 0.3 0.4 Bal. Ipp/A Ipb/A δ/% fL/Hz
ER2319 6.3 0.28 0.145 0.19 0.1 0.04 Bal.
1 170 – – –
2 240 100 50 1
3 240 100 50 2
that the high-frequency pulse is beneficial to the constriction of welding
4 240 100 50 3
arc as found by Yang et al. (2017), the increase of weld penetration
depth as indicated by Cook et al. (1985), the reduction of weld porosity
as shown by Yang et al. (2015), the refinement of weld zone grain
structure and the enhancement of mechanical properties of the welded
joints as described by Wang et al. (2017b). The low-frequency pulse
(0.5–10 Hz) modulation technology has been applied in the welding
process. With low-frequency pulse modulation, the stirring effect is
obviously enhanced, and the microstructure could be significantly re-
fined as demonstrated by Liu et al. (2013). Wang et al. (2018) reported
that it is flexible to balance the welding heat input and arc penetrating
ability through properly adjusting the pulse parameters. In order to
simultaneously exploit the advantages of high frequency pulse and low
frequency pulse, a double pulsed VPTIG (DP-VPTIG) welding process
was developed. In DP-VPTIG process, the traditional variable polarity Fig. 2. Measurement of arc characteristic sizes.
current waveform was modulated into low-frequency pulses in the
range of 0.5 to 5 Hz. Meanwhile, the high-frequency pulses ranging
through current regulation as revealed by Wang et al. (2018). As a
from 20 to 80 kHz were superposed on the positive stage of the variable
source of heat and force in the welding process, welding arc is critical to
polarity waveform. The DP-VPTIG welding process has been applied in
the formation of weld pool, the heat transfer in molten liquid, the mi-
the keyhole TIG welding of AA2219 aluminum alloy, showing the ad-
crostructure and mechanical properties of welded joints as described by
vantages of this process in the control of weld penetration depth

Fig. 1. Waveform of double-pulsed VPTIG.

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Y. Wang et al.
Fig. 3. Measurement of the weld pool width.
Fig. 4. Schematic diagram of the positions for testing.
Ghosh et al. (2008). To deeply understand the process characteristics of
DP-VPTIG welding, the arc profile characteristics, weld pool mor-
phology, weld zone microstructure and welded joint mechanical
properties of AA2219 aluminum alloy were investigated.
2. Experimental procedure
The parent material and filler material employed were AA2219
aluminum alloy and 1.2 mm diameter ER2319 wire, respectively. The
chemical composition of AA2219 and ER2319 was listed in Table 1. The
dimension of the work-pieces for butt welding was 200 mm × 100
mm×4 mm (length × width × thickness), and 120 mm × 60 mm×6
mm (length × width × thickness) for the observation of arc profile and
weld pool appearance. Prior to welding, the specimens were first de-
greased with acetone, then alkaline pickled by 10%NaOH solution, and
then washed with 15%HNO3 acid solution and dried in air. The
shielding gas adopted was pure argon (99.99%), and the electrode used
was 4 mm diameter cerium tungsten with a 30 ° cone angle in the front
tip.
Fig. 5. Dimension of the tensile specimens.
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Journal of Materials Processing Tech. 266 (2019) 255–263
The power source employed was a self-developed double pulsed
VPTIG welding machine, whose current waveform is demonstrated in
Fig. 1. As shown in the figure, the traditional variable polarity current
waveform was modulated into low-frequency pulses in the range of 0.5
to 5 Hz. Furthermore, the high-frequency pulses ranging from 20 to
80 kHz were superposed on the positive stage of the variable polarity
waveform. From the figure, TL is the period time of the low-frequency
pulse current, TH is the period time of the variable polarity current, tb is
the duration time of the low-frequency pulse base phase, tp is the
duration time of the low-frequency pulse peak phase, tHn is the duration
time of the negative stage in TH, tHp is the duration time of the positive
stage in TH, Ipp is the positive current value in tp, Ipn is the negative
current value in tp, Ibp is the positive current value in tb, Ibn is the ne-
gative current value in tb.
Since it has been experimentally and theoretically proved that the
high-frequency pulse current could obviously improve the welding
process. The parameters of high-frequency pulse current were set as
constant values (current amplitude 80 A, pulse frequency 20 kHz and
duty cycle 50%), aiming to enhance the welded joints properties. To
investigate the effects of the low-frequency pulse on the microstructure
and mechanical properties of the welded joints, four tests with different
low-frequency pulse frequencies were carried out, as listed in Table 2,
in which Test 1 was the conventional VPTIG as a comparison test. Test 2
was used for the observation of arc profile and weld pool appearance.
The other constant process parameters were fH 100 Hz, tHp:tHn 8:2,
welding speed 150 mm·min−1, wire feed rate 1.5 m/ min, argon flow
rate 15 L·min−1.
2.1. Welding arc profile and weld pool morphology
The arc profile was imaged by a high-speed camera (Mega75 K)
based vision sensing system equipped with a Navitar ZOOM 7000 typed
close-focusing macro lens. The camera was fixed perpendicular to the
moving direction of the welding torch, and the optical axis of the
camera was horizontally focused near the electrode tip. As illustrated in
Fig. 2, the arc profile characteristic sizes were defined as arc length L,
diameter DB at arc workspace end and diameter DE at arc electrode end.
In order to acquire the actual size of L, DB and DE, the 4 mm electrode
DR was selected as the reference dimension.
The appearance of the weld pool was captured by a BASLER
avA1000-120 km typed CCD camera equipped with a Computar M5018-
MP2 typed industrial lens. The lens was fitted with a narrow band filter
with a central wavelength of 1064 nm to eliminate the interference of
the strong arc light. The camera was set behind the welding torch with a
certain downward inclination angle, focusing on the area below the
electrode axis. Fig. 3 exhibits the image of the morphology of weld pool
observed by the CCD camera. To quantitatively describe the variation of
the weld pool appearance, the weld pool width Dw was defined as its
characteristic size. To determine the actual size of Dw, a steel ruler was
utilized as the reference dimension.
2.2. Microstructure and mechanical properties
The specimens for microstructure observation, micro hardness and
Y. Wang et al.
Fig. 6. Variable polarity current periods selected in a low-frequency pulse
period.
tensile testing were selected in the middle part of the welded joints, as
schematically displayed in Fig. 4. Metallographic samples were first
mechanically polished, and then etched by the Keller’s reagent solution
(HNO3: 2.5 ml, HCL: 1.5 ml, HF: 1 ml and H2O: 95 ml) prior to micro-
structure observation. Light microscopy (Axiocam 506 color) was used
to observe the microstructure. To determine the phase composition of
the welded joint, the D/Max-2200 pc typed X-ray diffract meter was
employed for X-ray diffraction (XRD) testing. The scanning electron
microscope (SEM) (Camscan-3400) equipped with an energy dispersive
spectrometry (EDS) tester was used for tensile fracture observation and
micro-area composition analysis. The micro hardness testing was car-
ried out by HVD-1000TEST digital Vickers (HV) hardness tester with
1.96 N load for 15 s. The tensile specimens were processed according to
standard metallographic procedures, as exhibited in Fig. 5. Tensile
testing was conducted at ambient temperature using an electronic
universal testing machine (HDW-50 K) with 2 mm/min loading rate.
3. Results and discussion
3.1. Arc profile characteristics
In DP-VPTIG welding process, the conventional variable polarity
current was modulated into low-frequency pulses. In each low-fre-
quency pulse peak stage and pulse base stage, there were a number of
complete variable polarity cycles. In order to completely investigate the
arc profile variation of DP-VPTIG, a variable polarity period was se-
lected from the pulse peak stage and pulse base stage, respectively, as
depicted in Fig. 6.
The variation of arc profile and its characteristic sizes in low-fre-
quency pulse peak stage (tp) and low-frequency pulse base stage (tb) are
exhibited in Fig. 7(a–c), respectively. During tp shown in Fig. 7a and 43
to 52 ms in Fig. 7c, it can be seen that the arc shape showed a significant
difference between the positive stage and negative stage. In positive
stage, DE, DB and L were relatively small, stable at 3.2 mm, 16.3 mm
and 6.9 mm, respectively. In negative stage, the arc shapes were largely
extended with DE, DB and L increasing to 3.8 mm, 19.2 mm and 7.7 mm,
respectively. This is mainly because of the cathode cleaning action of
the welding arc in negative stage, when the cathode spots can be ob-
served from the arc edge region at 51 ms and 52 ms in Fig. 7a. In tb
shown in Fig. 7b and 73 to 82 ms in Fig. 7c, the results showed that the
change trend of the arc profile was basically consistent with that in tp.
The main difference was that the arc characteristic sizes were all ob-
servably reduced due to the dramatic reduction in current amplitude.
DE, DB and L were stable at 2.7 mm, 10.3 mm and 6.5 mm respectively
in the positive stage, which were reduced by about 16%, 37%, and 6%,
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Journal of Materials Processing Tech. 266 (2019) 255–263
compared with that in tp. In negative stage, DE, DB, and L were stable at
3.3 mm, 11.7 mm, and 6.6 mm respectively, which were reduced by
about 13%, 39% and 14%, respectively.
Since the welding arc is the heat and force source of the welding
process, the periodic variation of the arc profile between the low-fre-
quency pulse peak stage and pulse base stage would lead to the periodic
variation of the arc energy and arc force, and further affect the melting
and flowing state of the weld pool.
3.2. Weld pool morphology
Fig. 8a and b reveal the dynamic variation of the weld pool mor-
phology and weld pool width Dw in a complete low-frequency pulse
period, respectively. During pulse peak stage (tp) from 100 to 500 ms,
the heat input was much larger due to the higher current amplitude
compared with that in pulse base stage (tb). In this stage, the parent
metal started to accelerate melting from the beginning of tp (100 ms).
As the peak current sustained, the parent metal continued to melt under
the effect of arc heat. Correspondingly, the weld pool width Dw in-
creased monotonously from 8.3 mm (100 ms) to 12.8 mm (500 ms).
Meanwhile, the weld pool surface was subjected to the arc force in
addition to the arc heat. The strong downward arc force overcame the
obstruction of the upward surface tension, leading to the obvious
downward movement of the weld pool surface below the arc axis, as
shown in the images at 300 to 500 ms. When the current was switched
to the pulse base stage (tb), the arc energy was observably reduced,
accompanied by a distinct reduction in optical radiation, which was
manifested by the darkening of the arc space. The heat input was
greatly decreased, and the liquid metal formed in tp started to gradually
cool and solidify from the tail and edge of the weld pool. At the same
time, the weld pool width Dw decreased from 11.5 mm (600 ms) to
8.5 mm (1000 ms). The arc force acting on the weld pool surface was
notably reduced and was not sufficient to overcome the upward effect
of surface tension. The liquid molten metal reflowed from the periphery
of the weld pool, and the depressed deformation of the weld pool sur-
face then disappeared.
3.3. Microstructure
Before microstructure observation, the X-Ray detection was per-
formed on the conventional VPTIG and 2 Hz DP-VPTIG welds, with the
images shown in Fig. 9a and b, respectively. There were no defects such
as cracks and pores inside the welds. Then the microstructure of weld
zone with VPTIG and DP-VPTIG in different low-frequency pulse fre-
quencies are exhibited in Fig. 10(a–d), respectively. As shown in the
figure, the weld zone was primarily composed of dark equiaxed den-
drite structure and light equiaxed non-dendrite structure. There were a
large amount of second phase particles distributing between the den-
drites and on the matrix phases. As the X ray diffraction (XRD) analysis
presented in Fig. 11, the phases existing in the welded joint were
mainly α-Al and θ phase (Al2Cu). The SEM micrograph with EDS results
are displayed in Fig. 12. It can be found that the black matrix structure
was α-Al, the white granular second phases were θ phase, and the white
net-like phases distributed along the grain boundaries were α+θ eu-
tectic structure.
From Fig. 10, it can be seen that the grain structure of DP-VPTIG
weld zone, especially at 2 Hz, was significantly refined and the dis-
tribution of the second phase particles was more uniform in comparison
to those of the conventional VPTIG. This is mainly because that the
periodic variation of the pulse current in DP-VPTIG process causes the
periodic variation of arc profile as well as the arc heat and force, en-
hancing the stirring effect on the weld pool, and further improving the
fluidity of the molten metal as demonstrated by Wang et al. (2017a).
The heat and mass transfer processes inside the weld pool is promi-
nently improved. Accordingly, the improvement of the heat transfer
process could greatly reduce the temperature gradient of the liquid
Y. Wang et al. Journal of Materials Processing Tech. 266 (2019) 255–263

Fig. 7. Arc profile and characteristic sizes variation in tp and tb.

metal in front of the solid-liquid interface, which is beneficial to the could be provided as the nucleation sites of the new grains, contributing
refinement of the grain structure (Hunt, 1984). The improvement of the to the refinement of the grain structure as indicated by Cong et al.
mass transfer process could obviously increase the diffusion rate of the (2009).
elements, thereby reducing the segregation of the Cu element. In con-
sequence, the distribution of the second phase particles is more even.
3.4. Micro hardness
Meanwhile, the strong stirring effect of the pulse current on the weld
pool can effectively break up the grown grains in the weld zone, in-
The micro hardness distribution along the transverse section of the
hibiting the growth of the grain structure. The broken grain particles
welded joints under conventional VPTIG and DP-VPTIG in different

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Fig. 8. Variation of the weld pool morphology and Dw in a complete low-frequency pulse period.

Fig. 9. X-Ray detection images of conventional VPTIG and 2 Hz DP-VPTIG welds.

low-frequency pulse frequencies is shown in Fig. 13. The results in- was a certain extent of reduction in the heat affected zone (HAZ) and
dicated that the micro hardness distribution of all the welded joints weld zone. The weld zone was the most severe softening area with
presented the same changing tendency. The parent metal possessed the micro hardness value ranging from 70 to 80 HV. This is primarily be-
highest micro hardness value in range from 130 to 140 HV, while there cause of the segregation of Cu element, which plays the main role in the

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Y. Wang et al.
Fig. 10. Micrographs of the weld zone under conventional VPTIG and DP-VPTIG in different low-frequency pulse frequencies.
Fig. 11. The XRD results of welded joint (DP-VPTIG 2 Hz).
solid solution strengthening of AA2219 aluminum alloy (Li et al.,
2015). During welding process, the cooling rate of the molten metal is
very fast, and it is easy to cause the incomplete diffusion of Cu element.
Fig. 14 shows the distribution of Al and Cu elements in the weld center.
It can be seen that the Cu element is mainly concentrated in the grain
boundary, and there exist some copper-depleted zones in the Al matrix,
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Journal of Materials Processing Tech. 266 (2019) 255–263
which would significantly reduce the solid solution strengthening effect
of the weld zone. From Fig. 13, the micro hardness of DP-VPTIG weld
zone is improved compared with that of the VPTIG weld zone (At pulse
frequency of 2 Hz, the micro hardness in weld zone were increased by
5–10%).
3.5. Tensile properties
The ultimate tensile strength (UTS), yield strength (YS) and elon-
gation results of the welded joints under conventional VPTIG and DP-
VPTIG in different low-frequency pulse frequencies are revealed in
Fig. 15. The UTS, YS and elongation of the parent metal were 458Mpa,
251Mpa and 12.3%, respectively. The tensile properties of the con-
ventional VPTIG welded joints were UTS 278 MPa, YS 150 MPa and
elongation 5.4%, which were 61%, 60% and 44% of the parent metal,
respectively. Compared with the conventional VPTIG, the tensile
properties of DP-VPTIG welded joints were improved. At pulse fre-
quency of 2 Hz, the tensile properties were UTS 299 MPa, YS 175 MPa
and elongation 6.6%, which were increased by 7.6%, 16.7% and 44%,
respectively. In comparison to the mechanical properties of AA2219
welds (micro hardness in the weld zone 74–76 HV, UTS 229 MPa, YS
125 MPa and Elongation 4.7%) produced by conventional TIG welding
as indicated by Rao et al. (2008), the mechanical properties are im-
proved with DP-VPTIG welding. The improvement of mechanical
properties in DP-VPTIG process is mainly due to the refinement of weld
zone grain structure caused by the stirring effect of the periodic var-
iation in arc profile.
Fig. 16(a,b) displays the appearance of tensile fracture surfaces with
Y. Wang et al. Journal of Materials Processing Tech. 266 (2019) 255–263

Fig. 12. SEM micrograph and EDS results of weld zone (DP-VPTIG 2 Hz).
Fig. 15. Tensile properties of the welded joints.

distributed on the fracture surface. Some small θ phase particles can be

observed at the bottom of the dimples (position B3).

4. Conclusions

The arc profile characteristics, weld pool morphology, weld zone

microstructure and welded joint mechanical properties of AA2219
aluminum alloy with double pulsed variable polarity tungsten inert gas
welding (DP-VPTIG) process were systematically investigated with
conclusions drawn as follows:

(1) The arc characteristic sizes arc length L, diameter DB at arc work-
space end and diameter DE at arc electrode end fluctuated peri-
odically with the low-frequency pulse.
(2) In pulse peak stage, the weld pool width Dw increased mono-
tonously, accompanied by a significant depressed deformation on
the weld pool surface. While, in the pulse base stage, Dw con-
tinuously decreased with the disappearance of the depressed de-
Fig. 13. Micro hardness distribution of welded joints under conventional
VPTIG and DP-VPTIG in different low-frequency pulse frequencies. formation.
(3) The weld zone was composed of matrix structure α-Al, granular θ
phase (Al2Cu), and net-like eutectic structure α+θ. Compared with
the conventional VPTIG, the weld zone grain structure of DP-VPTIG
EDS analysis at different positions under conventional VPTIG and DP- was refined, and the distribution of the second phase particles was
VPTIG at 2 Hz, respectively. The fractograph of conventional VPTIG more uniform. At pulse frequency of 2 Hz, the micro hardness in
weld is characterized by quasi cleavage fracture. A lot of brittle frac- weld zone were increased by 5–10%, and the ultimate tensile
tured eutectic particles (positions A2 and A3) were exposed on the strength (UTS), yield strength (YS) and elongation were increased
surface of fracture. The fractograph of DP-VPTIG presents typical duc- by 7.6%, 16.7% and 44%, respectively.
tile fracture characteristics with a large amount of dimples densely

Fig. 14. Elements distribution of weld center (DP-VPTIG 2 Hz).

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Fig. 16. SEM images of tensile fracture surface of conventional VPTIG and DP-VPTIG.
Conflict of interest
The authors declared that they have no conflicts of interest to this
work.
Acknowledgements
This work was supported by the Academic Excellence Foundation of
BUAA for PhD Students, State Key Lab of Advanced Welding and
Joining of Harbin Institute of Technology (AWJ-17M-01), Beijing
Natural Science Foundation (3182020), the National Natural Science
Foundation of China (51675031).
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