Development of Pulsed Cold Metal Transfer and Gas Metal Arc Welding Techniques on High-Strength Aerospace-Grade AA7475-T761

High-strength aluminum alloy (AA7475) sheets are widely used in aerospace sectors due to its better performance, global suitability, and multifunctional features. The welding of AA7475 in the fusion welding process like gas metal arc welding (GMAW) is difficult due to cracks generation. However, these problems could be overcome by different variants of GMAW process, like pulsed and normal cold metal transfer (PCMT and NCMT) techniques. The main objective of this research work is to deliver a better insight into mechanical and metallurgical properties of butt joint welded AA7475 through PCMT, NCMT, and GMAW techniques with ER5356 and ER4043. The defects-free butt joints were observed for PCMT, NCMT, and GMAW processes with ER5356, whereas the presence of porosities is found for ER4043. The microsegregation of Fe, Si, Mg, Zn, and Cu leads to the emergence of Mg₂Cu, Mg₂Si, Al₂Cu, Al₂CuMg, MgZn₂, Mg₂Zn₁₁, and Fe₂Al₆ phases in the AA7475 weldments. The development of binary brittle intermetallic Mg₂Si phase affects the tensile strength of all weldments made with ER4043. Better joint efficiency (96.11%), impact toughness (12.1 ± 0.8 J), and microhardness (119 ± 7.4 HV) are found in PCMT with ER5356 compared to other processes. Because of the low heat input utilised, PCMT provides better joint strength and microstructural integrity than NCMT and GMAW.