| Summary: | In this paper, a double pulse gas metal arc welding (DP-GMAW) for an AA6061-T6 aluminum alloy based on fewer basic welding parameters than the traditional DP-GMAW is proposed. This study compared the difference in pulse base currents (<inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><mrow><mi mathvariant="sans-serif">Δ</mi><msub><mi>I</mi><mi mathvariant="normal">b</mi></msub></mrow></semantics></math></inline-formula>) and the difference in the pulse peak currents (<inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><mrow><mi mathvariant="sans-serif">Δ</mi><msub><mi>I</mi><mi mathvariant="normal">p</mi></msub></mrow></semantics></math></inline-formula>) by analyzing the electrical signal and morphology properties of welded samples. The results indicated that changing <inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><mrow><mi mathvariant="sans-serif">Δ</mi><msub><mi>I</mi><mi mathvariant="normal">p</mi></msub></mrow></semantics></math></inline-formula> caused welding defects or even welding failure easily. The welding stability after changing <inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><mrow><mi mathvariant="sans-serif">Δ</mi><msub><mi>I</mi><mrow><mi mathvariant="normal">b</mi></mrow></msub></mrow></semantics></math></inline-formula> was much better than that after changing <inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><mrow><mi mathvariant="sans-serif">Δ</mi><msub><mi>I</mi><mi mathvariant="normal">p</mi></msub></mrow></semantics></math></inline-formula>. The individual fish-scale width of the weld joint remained unchanged when <inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><mrow><mo> </mo><mi mathvariant="sans-serif">Δ</mi><msub><mi>I</mi><mrow><mi mathvariant="normal">b</mi></mrow></msub></mrow></semantics></math></inline-formula> was at different values. In addition, the average absorbed work, tensile strength, yield strength and elongation of the weld joints obtained by different <inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><mrow><mi mathvariant="sans-serif">Δ</mi><msub><mi>I</mi><mrow><mi mathvariant="normal">b</mi></mrow></msub></mrow></semantics></math></inline-formula> values reached 31.1%, 60.2%, 52.9% and 37.9% of the base metal, respectively.
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