Interaction of welding method and joint geometry on the tensile performance of AA5052 aluminum alloy welds

This study experimentally investigates the combined influence of welding method and joint geometry on the tensile performance of 4 mm-thick AA5052 aluminum alloy joints. Six joint configurations, including conventional and structurally modified geometries, were fabricated using Gas Metal Arc Welding, Gas Tungsten Arc Welding, Shielded Metal Arc Welding, and Oxy–Acetylene Welding. Tensile tests were performed to evaluate strength, ductility, deformation response, and fracture behavior. The results demonstrated that both welding method and joint geometry significantly affected mechanical performance. The highest tensile strength, 199.88 MPa, was achieved in the GMAW-produced lap joint, corresponding to approximately 88% of the base material strength. The effect of joint geometry was non-uniform and strongly dependent on the welding method. GMAW and GTAW generally provided higher tensile performance due to stable arc characteristics, controlled heat input, and reduced defect formation. In contrast, SMAW and OAW showed lower performance in several configurations. PR-LJ and SJ provided more consistent performance across welding methods. Fracture analysis showed that high-strength joints predominantly failed in the heat-affected zone, whereas lower-performance conditions exhibited weld metal failure. Overall, tensile performance was governed by the interaction between welding method and joint geometry.