Investigation of Surface Welding Defects in EN AW 5083 HO Aluminum Plates Joined by Robotic GMAW Butt Welding Using Non-Destructive Testing Methods

The aim of this study is to systematically investigate the superficial weld defects that may occur after welding in 1.75 mm thick EN AW 5083 HO aluminium alloy sheets, which have high corrosion resistance due to their high magnesium content, using butt welding configuration and Gas Metal Arc Welding (GMAW) method. The ultimate goal is to determine the best welding parameters to improve the structural performance and service reliability of aluminium welded structures, especially in marine engineering applications. In the experimental study, EN AW 5083 HO aluminium sheets were prepared and then butt welded by robotic GMAW method under variable welding current and welding speed parameters. After welding, non-destructive testing methods such as visual inspection (ISO 17637), liquid penetrant test (ISO 3452-1), radiographic inspection (ISO 17636-1) were applied to the samples. The data obtained were evaluated to detect, classify and quantitatively analyse weld defects such as porosity, weld incompleteness, weld bead defects and surface cracks. The relationship between welding parameters and defect formation was analysed and the most suitable parameters were determined to obtain defect-free welds. The analyses showed a strong relationship between welding parameters and defect formation. High welding current and inappropriate feed rates were associated with increased porosity and lack of fusion; A significant reduction in surface defect rates and an improvement in weld seam quality were achieved with the best weld parameter determined. The results are reported in accordance with the acceptance criteria for aluminium welds specified in ISO 5817 standards.