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UNIVERSI TI TEKNIKAL MALAYS IA (UTeM)
Joining Performance of Aluminum T6063 Using
GMAW Welding
Dissertation Submitted of the Faculty of Manufacturing Engineering in
Partial Fulfillment of the requirement for The Awards of the Degree of
Bachelor of Manufacturing Engineering (Manufacturing Design)
Mohd.Azme1 Bin Aziz
APRIL 2008

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UTeM Library (Pind.112007)
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
JUDUL JOINING PERFORMANCE OF ALUMINUM T6063 USING
GMAW WELDING
SESl PENGAJIAN : 2005 - 2008
a ~ a MOHDAZMEL BIN AZlZ
mengaku membenarkan tesis (PSMISarjanalDoktor Falsafah) ini disimpan di
Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat
kegunaan seperti berikut:
1. Tesis adalah hak milik Universiti Teknikal Malaysia Melaka .
2. Perpustakaan Universiti Tekni kal Malaysia Melaka di benarkan mem buat salinan
untuk tujuan pengajian sahaja.
3. Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran
antara institusi pengajian tinggi.
4. **%la tandakan (4)
SULK
(Mengandungi maklumat yang berdarjah keselamatan
atau kepentingan Malaysia yang termaktub di dalam
AKTA RAHSIA RASMl 1972)
TERHAD (Mengandungi maklumat TERHAD yang telah ditentukan
oleh organisasilbadan di mana penyelidikan dijalankan)
TlDAK TERHAD
M.
(TANDATANGAN PENULIS)
Alamat Tetap:
N0.185-A KG TIT1 BESI,
06200 KEPALA BATAS,
ALOR STAR, KEDAH DARUL AMAN.
Tarikh: 3 a \ 5 / ~ d ~ & Tarikh: >a I $ / J O ~ $
I '
" Tesis dimaksudkan sebagai tesis bagi ljazah Doktor Falsafah dan Sarjana secara penyelidikan, atau
disertasi bagi pengajian secara kerja kursus dan penyelidikan, atau Laporan Projek Sarjana Muda (PSM).
'" Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan
denqan menvatakan sekali sebab dan temwh tesis ini perlu dikelaskan sebaqai SULIT atau TERMD.

UECLAKA'I'IUN
"I hereby declare that thrs wrltlng IS my ortglnal work except tor quotatlons and
summaries, each one of which I have clearly stated its source"
Author's Name MUW.ALMbL BIN ALlL

AYJ'KUVAL
"1 hereby declare that 1 have read the content ot the thes~s and In my oplnlon, the
content of the thesis have fulfilled the scope and quality for the purpose of achieving
the Degree ot Bachelor ot Manutactunng Englneenng (Manutactunng Ueslgn)"
Signature
Supervisor

Weldlng charactenstlcs ot Alumrnum '1'60b3 plate speclmen ot l Omm
thickness by a Gas Metal Arc Welding (GMAW) were studied. Generally, the
composltron tor thls senes whrch are 0.9% Magnes~um and 0.6Y0 Silicon are the
highest alloying elementq. The type ol'joining was studied in this research is Butt
Jolnt and thls research are also to be studled about their performance and capablllty.
These specimens wcrc welded by certiticd and skillful bvcldcr from Nautical Line
(M) Sdn-Bhd. In thls research, there are 3 characterlstlcs 01 Alumlnum '1'6063 to be
studied; impact, hardness and the defects in the joining. To perform this research,
Impact 'l'estmg Machlne, Kockwell Hardness Mach~ne, and Ultrasonic 'I'estlng
Machine are used to cany out the data to be analyzed.

Mengkaji tentang sitat-sitat bahan Alum~nium '1'6063 setebal l0mm apabila
ianya dikimpal menerusi kimpalan arka gas lengai (GMAW). Secara umumnya,
komposlsi kimia yang terbesar bag1 bahan in1 adalah 0.YYo Magnesium and 0.6Y0
Silicon. Penyambungan jenis 'temu' adalah yg di gunakan untuk penyelidikan ini
bag1 mengkajl tentang prestasi dan juga kebolehupayaanya. Spesimen yang dl
gunakan untuk diujikaji telah disediakan oleh Nautical Line (M) Sdn.Rhd menerusi
pengimpal yang berkemahiran dan juga terlatlh. VI dalam penyelidikan ini, tiga (3)
sifkt-sifat Aluminuim T6063 akan di kenalpasti iaitu daripada segi kekuatan impak,
kekerasan, dan juga kecacatan pada bahagian tempat penyambungan. Untuk
mengaplikasikan ujikaji ini, mesin-mesin yang digunakan adalah seperti Mesin Ujian
Impak, Mesin Ujian Kekerasan Kockwell, danjuga Mesin Ujian Ultrason~c.

k'irst oj all, all the praises and thanks he to Allah S. W. 7'jor His Love,
This thesis is dedicated to my.family,
1 b my beloved parent, Aziz Bin Harun & Juriah Ut Ahmad
And my truely lovely person, Norita bt Md Nusir
1hankyou vety muchjor your unstinting help and encouragement.

In the name of Allah, the most Gracious aud most Compassionate
Firstly, 1 want to to thank Allah Almlghty for blesslng me and glvlng me
strength to accomplish this thesis. I would like also to take this opportunity to gather
all my most slncere gratitude towards my gracious and benevolent supervisor, Mr.
Syahrul Aman bin Suandi for his proper guidance and generous assistance
throughout the accompl~shment of the work contarn In the thesis. 1 have benetltted
through his kind help, valucablc suggcstion and encouragcmcnt in completing my
work and complllng thts thesls.
1 would llke to express my earnest appreclatlon and thanks to Mr. Hadzley
bin Abu Bakar for providing helpful and significant information when i needed him
most. Many thank to all of the technlclans especially Mr. Azhar for their cooperation
and assisting me in the various laboratory tasks.
Last but not least, to those who contribute towards the accompl~shment of thls
thesis especially Apit Kacak, Mud4 Arin, Wak Din, Aman, Wan, and all my family
members, 1 ofler my deepest and genulne gratefulness for thew support, oplnlon and
suggestion.

'I'ABLE UP' CVN'I'EN'I'S
9eclaration.. ..................................................................................... I
. Approval ......................................................................................... 11
...
Abstract.. ....................................................................................... IIB
Abstrak .......................................................................................... iv
Uedication ...................................................................................... .v
Ackr~owlcdgement ............................................................................. vi
'I'able of Contents.. ........................................................................... vii
List of Figures .................................................................................. xi
List of 'l'ables
...
................................................................................. XIII
List uf Symbols ............................................................................... xiv
List of Abbreviation .......................................................................... xv
List of Appcndiccs.. .......................................................................... xvi
1.1 Background.. ......................................................................... I
1.2 Problem Statement.. ............................................................... .,2
1.3 ObJectlves.. ........................................................................ ..-2
1.4 Scope ................................................................................... 2
CHAYI'EK 2 : L1'l'k;KA'I'UKE KEVIEW
2.1 What IS Aluminum.. ............................................................... ..3
2.1 -1 Characteristics of Aluminum ................................................. ..4
2.1.2 Mechanical Properties of Alumlnum ......................................... -3
2.1.3 Applicatiotls.. ..................................................................... 6
2.2 'I'he Senal ot Alumlnum Alloys ..................................................... 6

2.3 Aluminum Boat ........................................................................ 8
2.3.1 Introduction ....................................................................... 8
2.3.2 Why Used Aluminum ............................................................ Y
2.4 Mechaitical PI-operties Background ............................................... 10
2.4.1 General Uetinttton ot mechanical Yropertles ................................ 11
2.5 Welding ............................................................................... I2
2.3.1 Introductton ..................................................................... 12
2.5.2 Gas Metal Arc Welding (GMAW) ........................................... 13
2.3.2.1 Yllnctple .................................................................... -13
2.5.2.2 Ftquipments .................................................................. 14
2.3.2.3 CiMAW Weldtng Shleldtng Gas .......................................... I3
2.5.2.4 Advatltages and Disadvantages of GMAW ............................. 15
2.6 lest .................................................................................... 16
2.6.1 Destructive 'l'est (NUI') ....................................................... 16
2.6.2 NonUestruct1ve'I'est(NU'1') ................................................. 16
2.7 lirlpact Test ......................................................................... 17
2.1. Advantages and Utsadvantages ot Impact 'l'est ............................ 1'1
2.7.2 Theory ............................................................................ 18
2.8 U ltrasonlc 'I'est ...................................................................... 1Y
2.8.1 Introduction ...................................................................... 19
2.8.2 'I'heory ............................................................................ I Y
2.8.3 Advantagcs and Disaclvantages of Ultrasonic Test ......................... 21
2.9 Hardness 'I 'est ........................................................................ ZL
2.9.1 Advantages of Hardriess Test .................................................. 22
2.9.2 Factors Involve Yertormed Hardness 'l'est ................................... ZZ
2.9.3 Types of Indcntcr ............................................................... 23
2.9.4 Hardness Scale .................................................................. 24
2.10 Matcrial at~d Standards ............................................................ 26

CHAPTER 3 : METHODOLOGY
3.1 lntroduction ......................................................................... 27
3.2 Experimental Apparatus ........................................................... 28
3.2.1 GMAW Welding Machine .................................................... 28
3.2.2 Band Saw Machine ............................................................ 30
3.2.3 Shielding Gas ................................................................... 31
3.2.4 Filler Rod ........................................................................ 31
3.3 Personal Protective Equipments (PPE) .......................................... 32
3.3.1 Shielding Mask ................................................................. 32
3.3.2 Leather Glove ................................................................... 33
3.3.3 Apron ............................................................................. 33
3.4 Testing Machines ................................................................... 34
3.4.1 Standard Operation Procedure (SOP) of Hardness ........................ 34
3.4.2 Standard Operation Procedure (SOP) of Impact ............................ 36
3.5 Experimental Methods ............................................................ -37
3.5.1 Design of Experiment (DOE) ................................................ 38
3.5.1.1 Specimens .................................................................... -38
3.5.2 Material Selection ............................................................... 39
3.5.2.1 Introduction .................................................................. 39
3.5.2.2 What is Aluminum T6063 .................................................. 39
3.5.2.3 The Composition of Aluminum T6063 ................................... 40
3.5.3 Welding Parameter ............................................................... 41
3 S.3.1 Welding Procedure ............................................................ 41
3.5.4 Specimen Preparation ............................................................ 46

CHAPTER 4 : RESULT AND DATA ANALYSIS
4.1 Result of Impact Test ................................................................ 47
4.1.1 Charpy Impact Test ............................................................ -48
4.1.2 Izod Impact Test ................................................................ 53
4.1.3 Summary ....................................................................... -57
4.2 Result of Rockwell Hardness Test ................................................ 58
4.3 Result of Non Destructive Test ................................................... 65
4.4 Final Result .......................................................................... 70
CHAPTER 5 : DISCUSSION .............................................................................. 71
CHAPTER 6 : CONCLUSION .......................................................... 76
CHAPTER 7 : SUGGESTION AND RECOMMENDATION ..................... 78
REFERENCES ................................................................................ 79
Appendix A : Figure and Table
Appendix B : Calculation For Impact Test
Appendix C : Result For Impact Test

NO
2.3.1
2.5.1
2.5.2
2.5.2.2
2.7 (a)
2.7 (b)
2.7.2
2.8.2 (a)
2.8.2 (b)
2.8.2 (c)
3.2.1
3.2.2
3.2.4
3.3.1
3.3.2
3.3.3
3.4.1
3.4.4
3.5
3.5.1.1 (a)
3.5.3.1 (1)
3.5.3.1 (2)
3.5.3.1 (3)
3.5.3.1 (4)
3.5.3.1 (5)
3.5.3.1 (6)
LIST OF FIGURES
ITEMS
Aluminum Boat
Welding Process
GMAW Welding Schematic Process
GMAW Welding Equipments
Izod Test
Charpy Test
Schematic Diagram of Impact Test
Incomplete of Fusion
Incomplete of Penetration
Porosity
GMAW Welding Machine
Band Saw Machine
Filler Rod
Shield Mask model S939
Leather Glove
Apron
Rockwell Machine
Impact Test Machine
Experimental Methods
Specimen for Impact Test
C02 Fire Extinguisher
Wire Installation
Setting the Roller Tensioner
Setting the Wire Reel Tensioner
Parameter Setup
Practice Before Welding
PAGES
8
12
13
14
17
17
18
20
20
2 1
28
3 0
32
32
3 3
3 3
3 5
36
37
38
4 1
42
42
43
43
44

3.5.3.1 (7)
3.5.3.1 (8)
3.5.4 (ii)
3.5.4 (iii)
3.5.4 (iv)
4.1
4.11 (a)
4.11 )
4.1.2 (a)
4.1.2 (b)
4.2 (a)
4.2 (b)
4.2 (c)
4.2 (d)
4.2 (e)
4.2 (f)
4.2 (g)
4.3 (a)
5
Examine the Welds
Removing the Oxide Layer
Cut off Raw Material Using Band Saw
Tap Well Process
Finished Product
Specimen for Izod Impact Test
Graph of Impact Energy versus Specimen for Charpy
Impact Test
Graph of Impact Strength versus Specimen for Charpy
Impact Test
Graph of Impact Energy versus Specimen for Izod
Impact Test
Graph of Impact Strength versus Specimen for Izod
Impact Test
Specimen Tested
Ball Indenter 1/16
Graph Result of Rockwell Hardness Test
Graph of Average Hardness Value by Point of Specimen
Graph Specimen 1B
Graph Specimen 1C
Graph of Average Hardness Value by Specimen
Specimen
Specimen Cross Section
44
45
46
46
46
47
49
5 1
54
56
58
5 8
59
61
62
63
64
65
73

TABLE
1
2
3
4
5
6
7
8
9
10
1 1
12
13
14
15
16
17
18
19
20
2 1
22
23
24
25
26
LIST OF TABLES
ITEMS
Characteristics of Aluminum
The Serial of Aluminum Alloys
Definition of Mechanical Properties
Advantages and Disadvantages of GMAW
Advantages and Disadvantages of Impact Test
Advantages and Disadvantages of Ultrasonic Test
Factors Involve Performed Hardness Test
Types of Indenter
Material and Standards
GMAW Machine Specification
Band Saw Machine Specification
Recommended Shielding Gas
The Composition of Aluminum T6063
Welding Parameter
Data Collection of Charpy Impact Test
Data to Calculate Impact Strength for Charpy Impact Test
Data to Calculate Impact Energy for Izod Impact Test
Data to Calculate Impact Strength for Izod Impact Test
Result for Impact Test
Parameter for Hardness Test
Result of Rockwell Hardness Test
Result of Non Destructive Test
Result of Mechanical Properties for Aluminum T6063
Result for Impact Test
Recommended Parameter Setting for Joining Aluminum
Using GMAW
Parameter Setting for Joining Aluminum Using GMAW at
Nautical Line (M) Sdn.Bhd.
xiii
PAGES
4
6
11
15
17
2 1
22
23
26
29
30
3 1
40
4 1
48
50
53
5 5
5 8
59
6 1
69
7 1
73
75
76

Yo
Oc
MPa
A l
>
<
C02
02
H
91
92
m
H
0
Percentage
Degree Celsius
Megapasal
Aluminum
Bigger
Smaller
Carbon Dioxide
Oxygen
LIST OF SYMBOLS
Height of Pendulum
Degree of Pendulum
Degree After Impact
Mass
Gravity
Height
Degree
Kilogram
millimeter
Voltage
Ampere
Hertz
Rotational Per Minute
Kilowatt
Diameter
Joule
Joule per Meter Square
Meter Square

LIST OF ABBREVIATIONS AND SPECIALIZED NOMENCLATURE
GMAW
DT
NDT
UTeM
GTAW
CPU
MIG
DC
TIG
SMAW
AC
NDE
NDI
HB
HK
HR
HV
UTS
PPE
SOP
DOE
SEM
UTM
ASME
ASTM
HAZ
Gas Metal Arc Welding
Destructive Test
Non Destructive Test
Universiti Teknikal Malaysia Melaka
Gas Tungsten Arc Welding
Central Processing Unit
Metal Inert Gas
Direct Current
Tungsten Inert Gas
Stick Metal Arc Welding
Alternate Current
Non Destructive Evaluation
Non Destructive Inspection
Brinell Hardness Number
Knoop Hardness Number
Rockwell Hardness Number
Vickers Hardness Number
Ultimate Tensile Strength
Personal Protective Equipment
Standard Operation Procedure
Design of Experiment
Scanning Electron Microscope
Universal Testing Machine
American Society of Mechanical Engineering
American Society of Testing for Materials
Heat Affected Zone

Appendix A : Figure and Table
LIST OF APPENDICES
Appendix B : Calculation For Impact Test
Appendix C : Result For Impact Test

1.1 Background
CHAPTER 1
INTRODUCTION
Nowadays, Aluminum is widely used in many sector or industries such as
automotive, aircraft, watercraft, and others. This research is to study about the welding
performance of specific parts in boat manufacturing. Beside that, it also focuses about
the joining in terms of hardness, impact, strength, and metallurgy. For the joining, Gas
Metal Arc Welding (GMAW) is used to join the material before proceeds to the next
stage. The type of joining is focused to Butt join. It is because; this joining is mostly
used in boat manufacturing. Aluminum T6063 is used for this research because the
material is provided by the boat manufacturer, Nautical Line (M) Sdn.Bhd, Kedah.
Mechanical properties for materials are important to be tested in order to make
sure the products that to be produced have a good quality and good physical strength
which depend on the material used. The properties are referring to the ability of the
material to get through any stress or defection which can affect the product physically.
There are several testing involve in this research. For Destructive Test (DT), impact test
and hardness test are used. While Ultrasonic for Non Destructive Test (NDT).

1.2 Problem Statement
The Aluminum boat in Malaysia is still lacking in terms of the use of welding
techniques as well as joining performance testing. The present research will describe the
details information about welding performance of specifics parts in boat manufacturing.
Previously, there is no standard testing to evaluate the stability of boat especially in
materials effect of joined parts. Thus, the research will focus on the analysis of specific
joining parts in terms of hardness and impact strength. The materials Aluminum T6063
will be provided by the boat manufacturer, Nautical Line (M) Sdn. Bhd, Kedah and the
testing evaluation will be held in UTeM.
1.3 Objectives
(a)
(b)
1.4 Scope
(a)
(b)
(c)
To be able to analyze the characteristics of Gas Metal Arc Welding
(GMAW) of Aluminum T6063 in terms of hardness and impact.
To be able to compare the welding performance between experimental
method and industrial practice.
Details study on Aluminum T6063 in application for boat industries.
Details study on material testing of joining products such as impact test,
hardness test, and nondestructive test (NDT).
Welding practical to produce the required product

2.1 What is Aluminum?
CHAPTER 2
LITERITURE REVIEW
Aluminum is the most common metallic element on earth. This material is
making up about 8% of the earth's crust and it's concentrated in the outer 16 km. Only
Oxygen and Silicon are more abundant. Evolution of life and human civilization has
developed Aluminum in rich environment. It is the most widely used non-ferrous metal
today. Aluminum never occurs in its metallic form in nature. It occurs in various forms
in most rocks and soils and is also present in gemstones like topaz and garnet. It can be
found in vegetation and in all of the earth's water. Aluminum is also present in all clays,
so it has been a constituent of cooking vessels since earliest civilizations.
The naturally occurring forms of Aluminum are usually stable and do not interact
with the biological processes of living organisms. Under acidic conditions Aluminum
may be released from rocks and soils in a soluble form which is more available for
uptake by plants and animals. However, uptake of this soluble form is limited by the
presence of natural agents such silicates and fluorides.