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The mechanical properties and microstructural features of 1561 aluminum alloy weldments processed by single-wire MIG welding and CMT TWIN welding are investigated. The microstructure and mechanical properties of welded joints were studied by nondestructive testing, metallurgical test, scanning electron microscopy test, fatigue and tensile test. It is revealed that the welding efficiency of CMT TWIN welding is more than six times as much as single-wire MIG welding. It can be easy to find weld zone (WZ), fusion line (FL), heat affected zone (HAZ) and base metal (BM) with different characteristics in the metallographic specimen. In weld zone, the particle phase sizes are smaller than that of base material, but the densities of particle phase are increased. The sample fatigue strength of CMT TWIN welding is higher than the singe-wire MIG welding. It is suggested that the CMT TWIN welding has several advantages compared with single-wire MIG welding.

Plasma-MIG hybrid welding and MIG welding of 5083 marine aluminum alloy was carried out. The influences of parameters of welding process on the weldments morphology were investigated in order to optimize the welding process parameters. The macrostructure, microstructure, tensile and bending properties of the optimized joint were studied. The results show that Plasma-MIG hybrid welding not only has a synergistic effect of Plasma and MIG welding but also has a high welding efficiency. Welding speed, Plasma current and MIG current have a significant effect on welding penetration and welding morphology. Meanwhile, the ductility and strength property of weld joint was qualified though the bending test and tensile test. The average tensile strength of weld joint is about 285MPa at room temperature, about 86% of the base metal.

A series of slag were fabricated by self-shield welding of different flux-cored wire. The microstructure and phase composition of those slag were investigated by means of metallographic microscope, SEM,EDX and X-ray diffraction respectively. The result demonstrated that the slag forming material of TiO2 and Al2O3 tenders to form the framework structure of slag, while CaO and MnO2 inclines to incorporate in the grain boundary. Furthermore, the dense and dendrite phase structure of slag was beneficial for the removal of slag. On the contrary the slag with tiny needle and skeleton-like structure was difficult to clear up. In conclusion, the detachability performance was not only affected by the microstructure, but also by the chemical composition of the slag system.

Using the prepared gas-shielded flux-cored wire for welding 600MPa high strength steel, the 921A high strength steels were welded at different weld heat input condition of 10 kJ/cm, 15 kJ/cm and 20 kJ/cm. The influence of weld heat input on the electrochemical behavior of the 921A high strength steel welding joints were studied in this paper. The results show that, at different weld heat input condition, the linear polarization resistances (LPR) of all the welding joints welded by using the prepared flux-cored wire were close to that of the 921A base steel, as can be identified as the same LPR value at 15 kJ/cm weld heat input condition. By observing the surfaces of the linear polarized welding joints samples, it was found that the welding joint at 15 kJ/cm weld heat input had the smallest corrosive area by macro observing, showing the pitting corrosion by micro observing and presents the least corrosion pit.