Microstructure and Properties of CMT+P Welded Joints of Aluminum Alloys for Battery Boxes

LI Yang; DING Tongming; SONG Zhenghao; LI Tianqing; ZHAO Guoping

doi:10.3969/j.issn.1674-6457.2026.05.009

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Journal of Netshape Forming Engineering ›› 2026, Vol. 18 ›› Issue (5) : 101-113. DOI: 10.3969/j.issn.1674-6457.2026.05.009

Advanced Joining Technology

Microstructure and Properties of CMT+P Welded Joints of Aluminum Alloys for Battery Boxes

LI Yang¹, DING Tongming², SONG Zhenghao¹, LI Tianqing^1,3,*, ZHAO Guoping¹

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Abstract

The work aims to provide basic data and theoretical guidance for CMT+P welding production of 6061/5083 aluminum alloys for battery boxes. The CMT+P welding experiments were conducted on 6061/5083 aluminum alloys. The metallography, XPS, SEM, EDS, EBSD, and other methods were used to characterize microstructure or phase composition and test microhardness, tensile strength, and salt spray corrosion resistance. Both ER4043 and ER5356 welding wires could produce well-formed welds when used to 5083/6061 aluminum alloys. Analysis of the weld spatter near the ER5356 weld bead suggested it primarily consisted of magnesium oxide and magnesium carbonate and the formation of weld spatter was mainly due to the evaporation of magnesium during welding. Compared to the microstructure of ER5356 welds, the precipitates in ER4043 welds were more uniformly distributed, and the average grain size in ER4043 welds was larger, increasing by 9 μm compared to ER5356 welds. Compared to the tensile properties of ER5356 welds, the average tensile strength of ER4043 welded joints was reduced by 6.9 MPa, and the average elongation was reduced by 2.5%. However, the tensile properties of the two wires were not significantly different, with tensile specimens fracturing in the heat-affected zone on the 5083 side. The average corrosion rate of ER4043 welded joints was 7.143 g/(m²·h), while that of ER5356 welded joints was 5.020 5 g/(m²·h). Additionally, the number and size of corrosion pits in ER4043 welds were greater than in ER5356 welds, indicating poorer corrosion resistance for ER4043 welds. The surface formation of ER4043 welds is superior to ER5356 welds, but the strength of ER4043 welded joints is slightly lower than that of ER5356, and the corrosion resistance of ER4043 welded joints is also inferior to ER5356 under salt spray corrosion. Unless corrosion resistance is a primary concern, ER4043 can be used as a substitute for ER5356 welding wire.

Key words

CMT+P welding / dissimilar welding wire / aluminium alloy / weld formation / salt spray corrosion

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LI Yang, DING Tongming, SONG Zhenghao, LI Tianqing, ZHAO Guoping. Microstructure and Properties of CMT+P Welded Joints of Aluminum Alloys for Battery Boxes[J]. Journal of Netshape Forming Engineering. 2026, 18(5): 101-113 https://doi.org/10.3969/j.issn.1674-6457.2026.05.009

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