The Tungsten Inert Gas (TIG) welding processes one of the prevalent methods used for welding aluminum alloys. TIG welding is most commonly used due to its superiority in welding less dense materials. The most prevalent issues encountered with TIG welding aluminium alloys are porosity creation and cracking due to solidification, both of which result in lower mechanical properties. Because of the metal’s susceptibility to heat input, this occurs. The current work is the result of a desire to improve the mechanical properties of dissimilar aluminium metals: AA5052-H32 & AA5083-H111. The process parameters of TIG welding are optimized towards eliminating the previously discussed failure scenarios. Various optimization techniques exist towards obtaining optimizing processes such as Response Surface Methodology (RSM), Genetic Algorithm (GA), Artificial Neutral Network (ANN), Flower pollination algorithm, Taguchi method etc, The Taguchi method was chosen for the optimization of process parameters due to its inherent nature of solving problems of singular variance. The optimal parameters combination was determined i.e. welding current at 170 A, filler rod diameter 2.4 mm and Gas flow rate of 11 lpm. The optimized input parameter was used to TIG weld the confirmation specimen which are further investigated for mechanical and metallurgical characterizations. The parameters were optimized and the results indicate that the input current was found to be the most contributing towards improving mechanical properties over all the process parameters.

This paper is focused on investigating the mechanisms associated with different failure modes of copper (C101) sandwich panels with honeycomb cores of different heights subjected to flexural loading. Honeycomb core is made up of copper strips which were formed to required shapes using Dies fabricated by Electric Discharge Wire cut machining technique. All the joints in the sandwich panel were established through Brazing technique. Three-point bending test was conducted as per ASTM standard C-393. It was observed that increase in height of the core resulted in panels with higher strength to weight ratio. It also exhibited higher stiffness to weight ratio and very high strain energy absorption ability. An increase in flexural strength was reported with a maximum of 43% improvement for 10.9 mm core compared to 6.9 mm core. Further, 81.75% increase in absorbed strain energy was reported for 10.9 mm thick panel compared to 6.9 mm. The Optical and scanning electron microscope (SEM) analysis confirmed the establishment of good bonding between the filler and the substrate. Energy-dispersive Spectroscopic (EDS) analysis revealed the presence of Cu, Al, Zn, SiO2 and CaCO3 in the substrate. Further it also revealed the presence of Cu, CaCO3 and GaP in the filler material. The failure mode map was constructed which can be used for predicting different types of failures more likely to occur for specific parameters of copper sandwich panel. The dominant failures occurred during testing was in good agreement with the prediction done through failure mode map. The appreciable results in the proposed research may be supportive in construction of cooling system. The structure development and process control are convenient in mass production in automobile industries.