Product quality optimization strategies for electron beam welding process for thin plates of aluminum alloy 6061

Abstract This paper examines electron beam welding of thin plates (2 mm to 4 mm) made of Aluminum alloy 6061 using the kinetic energy of a high-power density electron beam, which locally heats the joint area to temperatures significantly exceeding the melting point of the material. Regression models have been estimated for the geometric characteristics of the fusion zone (length of the fusion zone, width of the fusion zone, cross-sectional area of the fusion zone) depending on the electron beam power, welding speed, and plate thickness. Based on these models, mean value and variance models have been constructed, and a multi-criteria optimization of the process parameters and geometric characteristics of the fusion zone in electron beam welding of Aluminum alloy 6061 has been implemented.