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Abstract
The present investigation aims to contrast the effect of the commonly used thermal frequency on welding process suitability, weld profile, weld macrostructure, and weld hardness on AA6061 aluminum alloy double pulsed gas metal arc welding. Material manufacturing processes and welding parameters with thermal frequencies of 2, 3, and 4 Hz are described in detail. Three defect-free welds were successfully formed at these thermal frequencies. The results indicate the following: (1) thermal frequency has no effect on welding process suitability when the welding parameters are self-matching; and (2) at increased thermal frequency, weld ripple distance reduces, maximum penetration depth decreases, grain size of the fusion zone decreases, and fusion zone hardness increases.