Jurnal Dinamika Vokasional Teknik Mesin Vol.
No.
April 2025, pp.
https://journal.
id/index.
php/dynamika/issue/view/84120 ISSN: 2548-7590.
DOI: 10.
21831/dinamika.
Optimizing of Groove Angle in Welding Cast Aluminum A356 for Product Repair Heri Wibowo1*.
Arif Marwanto1.
Raka Hilmi Syah Putera1.
Ardani Ahsanul F2 1 Department of Mechanical and Automotive Engineering.
Vocational Faculty.
Universitas Negeri Yogyakarta 2 Department of Mechanical Engineering Education.
Faculty of Engineering.
Universitas Negeri Yogyakarta
Article Info
ABSTRACT
Article history:
The purpose of this study was to investigate the effect of groove angle on the tensile strength, impact toughness, and hardness of A356 cast aluminum and to determine the most optimal groove angle for welding A356 cast aluminum.
The research method used was a pure experiment by conducting tensile, impact, and hardness tests on welding specimens with groove angles of 0A, 30A, 55A, and 75A.
The test results showed that the 75o groove angle had advantages over other groove angles with a maximum stress of 26.
396 N/mm2, a maximum strain of 10.
341%, an elastic modulus of 1625.
144 N/mm 2, an impact toughness of 0.
1518 J/mm2, and a Vickers hardness of 24.
HVN.
Based on the test results, it was concluded that the groove angle of 75o is the most optimal angle for welding A356 cast aluminum in the context of repairing cast aluminum products.
Received Apr 10, 2025 Revised Apr 14, 2025 Accepted Apr 20, 2025 Published Apr 30, 2025 Keywords:
Cast product Cast aluminum Groove angle Impact test Tensile test Corresponding Author:
Heri Wibowo Department of Mechanical and Automotive Engineering.
Vocational Faculty Universitas Negeri Yogyakarta 55281 Sleman.
Yogyakarta.
Indonesia Email: heri_wb@uny.
INTRODUCTION
Technological advances and innovations, the manufacturing industry in this era continues to evolve, resulting in increased efficiency, better product quality, and greater production flexibility.
Technologies such as automatic welding, laser welding, and other advanced welding methods have increased production efficiency, precision, and speed.
These innovations not only allow welding on various types of materials, but also improve the quality of the resulting joints, reduce defects, and increase the durability of the final product (Ramadhan et al.
, 2.
A356 cast aluminum is an aluminum alloy that is often used in industrial castings because of its good characteristics and the ability to improve its mechanical properties through heat treatment (Davis.
After casting.
A356 cast aluminum has high strength, corrosion resistance, and the ability to be formed into complex shapes.
The heat treatment process can further improve its mechanical properties.
Many industries, such as machine manufacturing, the automotive industry, and construction use A356 Jurnal Dinamika Vokasional Teknik Mesin.
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52 cast aluminum to make complex components with tight tolerances.
The heat treatment process after casting is often carried out to increase strength, hardness, and fatigue resistance.
In welding, the bevel angle is very important because it affects weld penetration, current control, and final quality.
The right angle ensures optimal penetration and prevents deformation, so experience in selecting the bevel angle is very important (Rahmatika et al.
, n.
A356 cast aluminum is a commonly used alloy in the casting industry due to its good mechanical properties and further enhancement through heat treatment.
This alloy is used in various industries to produce components with tight tolerances and high strength (Kaufman, 2.
In a wheel rim casting industry in Yogyakarta, there was a problem of defective wheel rim products from A356 aluminum casting so that repairs were needed by welding.
In welding A356 cast aluminum for repair purposes, the selection of groove angle and electrode type has a significant effect on the final welding results.
There were several influences from both factors such as the selection of the right groove angle is very important in welding A356 cast aluminum for repair purposes.
Previous studies had shown that variations in groove angle have a significant effect on the mechanical properties of welded joints, for example a study on welding aluminum 6061 using the GTAW (Gas Tungsten Arc Weldin.
method showed that variations in groove angle affect the mechanical strength of the material with a thickness of 6 mm, where angles of 90 A and 60 A give different results in terms of tensile strength and joint quality (Husnul Fata et al.
, 2.
Other studies had shown that variations in groove angles in 6061 aluminum welding using the GTAW method, such as 60A and 80A, provide different tensile strengths, with 80A producing a maximum average tensile strength of 27 MPa and a strain value of 21.
02% (M.
Almanda et al.
, 2.
A study by (Zhang et al.
, 2.
showed that the right groove angle can reduce porosity and increase tensile strength in 6x series aluminum welding.
Meanwhile, research by (Kumar et al.
, 2.
identified that a smaller groove angle tends to produce deeper penetration but risks causing cracking if not properly controlled.
Research by (Yang et al.
, 2.
showed that the combination of optimal groove angle and TIG welding parameters can produce welded joints with strength equivalent to the base material.
These studies have not specifically discussed the A356 alloy, the results can be used as a reference in determining the optimal groove angle for welding this alloy.
The optimal groove angle also helps achieve the desired penetration into the material, which is crucial for maintaining the strength and structural integrity of the repaired area, as well as improving the quality of the weld by reducing the risk of underfilling and ensuring good filling of the damaged The purpose of this study was to investigate the effect of groove angle on the tensile strength, impact toughness, and hardness of A356 cast aluminum and to determine the most optimal groove angle for welding A356 cast aluminum.
Jurnal Dinamika Vokasional Teknik Mesin.
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METHOD
This study used a pure experimental method that aims to determine the best groove angle variation in A356 cast aluminum welding.
This study used independent variables in the form of 4 groove angle variations, namely 0o, 30o, 55o, and 75o.
Furthermore, there were 3 dependent variables in this study, namely tensile strength testing, impact toughness testing, and vickers hardness testing of A356 aluminum welding results.
The replication of specimens carried out in each test amounted to 3 specimens and the average value was taken.
The beak angle was varied between 0o to 75o based on the research of (Yang et al.
, 2.
on aluminum welding which showed the highest tensile strength was obtained at a current of 130 amps with a beak angle of 80A, reaching 150.
4 N/mmA.
Likewise, the highest strain value at a beak angle of 80A is 0.
Welding Process The welding process of A356 aluminum uses GTAW (Gas Tungsten Arc Weldin.
or TIG welding with groove angle variations of 0o, 30o, 55o, and 75o, using ER4043 filler.
Table 1 shows the parameters of A356 aluminum welding.
Table 1.
Welding Parameters No.
Materials Welding process Electrode Weld current Polarity Shielding Gas Welding groove Weld position Welding parameters Aluminum A356 TIG (Tungsten Inert Ga.
ER 4043 195 Ampere Argon Square Groove .
V Groove .
o, 55o, 75.
Design of Groove The welding process on A356 aluminum uses 2 types of grooves, namely Square Groove and V Groove.
Square Groove for angles of 0o and V Groove for angles of 30o, 55o, and 75o as shown in Figure Figure 1.
Design of Groove Tensile Test Specimen Jurnal Dinamika Vokasional Teknik Mesin.
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54 The tensile test specimen is the result of welding A356 cast aluminum and machined with a milling machine to form a curve.
Figure 2 is the size of the tensile test specimen based on the ASTM standard from the welding results of A356 aluminum in the center of the test specimen.
Figure 2.
Dimension of tensile test specimen.
Impact Test Specimen The impact test specimen uses a charpy impact specimen design.
After the welding process, the specimen goes to the machining process to obtain the size according to the charpy impact design.
Figure 3 is the size of the impact specimen from A356 aluminum welding used for toughness testing.
Hit direction Notch Figure 3.
Dimension of impact test specimen.
Hardness Test Specimen To facilitate the Vickers hardness test, after the welding process the specimen goes to the machining process to obtain the size according to the design.
Figure 4 is a design image of the welding results of A356 aluminum used for the Vickers hardness test.
Furthermore, the Vickers hardness test was carried out with a load of 60 kg and the indentation size on the specimen was investigated to determine the hardness value.
Figure 4.
Dimension of hardness test specimen.
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RESULTS AND DISCUSSION
Tensile Test Results After conducting tensile strength tests on welding specimens with variations of angles 0 o, 30o, 55o, and 75o, the results of the tests that have been carried out are then presented in a diagram to compare one specimen with another which will then be explained as follows:
Tensile Strength Value From the results of the tensile strength test carried out, each specimen with different groove angle variations shows different average stress values.
The tensile test results are shown in Figure 5 which is a diagram of the average tensile strength values of 3 specimens with the same variables.
Ultimate stress (N/mm.
36,542 55 angle 75 angle 0 angle 30 angle Groove angle variation Figure 5.
Ultimate tensile strength diagram From Figure 5, it can be seen that the specimen with a groove angle variation of 0 o obtained the lowest average tensile strength value of 27.
13 N/mm2.
Then the specimen with a groove angle variation of 55o produced the highest average tensile strength value of 36.
54 N/mm2.
This phenomenon occurs because at a groove angle of 0 the joint at the weld root does not diffuse well so that the strength is not Furthermore, at groove angles of 55o and 75o the diffusion of the weld metal with the parent metal is good so that it has a maximum value.
This is in accordance with the findings of (Naufal et al.
that the groove angle in welding greatly affects the mechanical strength of the weld joint.
Figure 6.
Fracture results of tensile test: .
groove angle 0 o, .
groove angle 30o, .
groove angle 55o and .
groove angle Figure 6 shows the fracture form of tensile test results.
Based on the image, it shows a brittle fracture phenomenon, considering that there is no necking in the test object.
The fracture results for Jurnal Dinamika Vokasional Teknik Mesin.
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56 groove angles 30o, 55o and 75o are also located in the parent metal of Aluminum material, which indicates that the weld strength has met the welding tensile test standards (Zhou et al.
, 2.
Strain Value From the results of tensile strength testing carried out on each specimen with different groove angle variations, it shows different average strain values.
Figure 7 is a diagram of the average strain values of 3 specimens with the same variables.
Elongation (%) 0 angle 30 angle 55 angle 75 angle Groove angle variation Figure 7.
Diagram of average strain value in tensile test From figure 7, it can be seen that the specimen with a groove angle variation of 0o obtained the lowest average strain value of 4.
Then the specimen with a groove angle variation of 75o produced the highest average strain value of 6.
Thus, we can conclude that the groove angle variation of 75o has the best level of ductility because it has the highest strain.
Impact Test Results After conducting Charpy impact toughness tests on welding specimens at angle variations of 0o, 30o, 55o, and 75o, the results of the tests that have been carried out are presented in a diagram (Figure .
to compare one specimen with another.
Impact toughness (J/mm.
0 angle 30 angle 55 angle 75 angle Groove angle variation Figure 8.
Impact Test Result Diagram Jurnal Dinamika Vokasional Teknik Mesin.
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57 From Figure 8, it is known that the specimen with a groove angle variation of 0o obtained the lowest average impact toughness value of 0.
036 J/mm2.
Then the specimen with a groove angle variation of 75o produced the highest average impact toughness value of 0.
130 J/mm2.
The welded joint at a groove angle of 75o showed the best impact toughness because at this groove angle it provided very good diffusion between the weld metal and the parent metal.
The impact toughness value is generally considered low, indicating brittle fracture.
This is caused by the grain boundary strength being stronger than the grain strength so that the fracture path splits the grains in the specimen (Malik et al.
, 2.
Hardness Test Results Hardness tests were conducted on the weld metal of the welding area.
After conducting the Vickers hardness test on the welding specimens at various angles of 0o, 30o, 55o, and 75o, the results of the tests that had been conducted were presented in a diagram (Figure .
to compare one specimen with Hardness (VHN) 0 angle 30 angle 55 angle 75 angle Groove angle variation Figure 9.
Diagram of hardness test results.
From Figure 9, it is known that the level of weld metal hardness in the specimen with a groove angle variation of 55o gets the lowest average Vickers hardness value of 26.
2 VHN.
Then the specimen with a groove angle variation of 0o produces the highest average Vickers hardness value of 31.
5 VHN.
At a groove angle of 75o, the Vickers hardness value is 28.
7 VHN.
This shows that the surface hardness of the weld metal has almost the same value because the welding process uses the same welding The difference in hardness values is more due to the cooling rate after the welding process, with the rate of speed at a groove angle of 0o being the fastest so that it tends to produce higher hardness (Wang & Zhang, 2.
From the tests that have been carried out, it was found that the best repair specimen was obtained in welding with a groove angle variation of 75o.
The repair specimen with a groove angle of 75o has a tensile strength value of 35.
89 N/mm2, a strain value of 6.
74%, an impact toughness value of 0.
13 J/mm2, and a Vickers hardness value of 28.
7 VHN.
Jurnal Dinamika Vokasional Teknik Mesin.
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58 Based on the results of the study above, data was obtained that was less linear with other This difference is possible due to the use of manual welding which depends on the condition of the welder.
This is a weakness of the study which can later be followed up with the use of automatic welding to reduce data bias.
CONCLUSION
Based on the results of the study conducted on A356 cast aluminum welding, the following conclusions can be drawn:
Specimens with 75o groove angle variation welding obtained a tensile strength value of 35.
N/mm2, a strain value of 6.
74%, a hardness value of 28.
7 VHN and the highest impact strength 13 J/mm2.
Thus, 75o groove angle variation welding has a superior impact strength than other groove angle variation specimens.
The 75o groove angle variation can be used as a solution in selecting the groove angle based on the mechanical properties and results of the tests that have been carried out because it has an average value that is superior to other groove angle variations.
ACKNOWLEDGMENT
We express our deepest gratitude to all parties who have supported the completion of this research article.
Special thanks to partner CV.
C Maxi alloyed for their support in this research.
This research can be carried out with financial support from the Faculty of Vocational Studies.
Yogyakarta State University in 2024 through contract number: T/1376.
22/UN34.
19/PT.
01/2024.
REFERENCES