A-TIG welding in aerospace industry: mechanisms, parameters, material considerations, optimization strategies, and machine learning integration

Abstract

Aerospace manufacturing relies on advanced materials and precise welding techniques to ensure structural integrity and performance. Traditional fusion welding methods, solid-state welding, and high-energy beam welding are commonly been used for these alloys. This review examines recent advancements in activated tungsten inert gas (A-TIG) welding for aerospace alloys, including nickel-based, aluminium, titanium, and steel. The use of activated fluxes in A-TIG welding, an enhancement of gas tungsten arc welding (GTAW), improves weld penetration, refines grain size, reduces porosity, and enhances weld quality, resulting in higher tensile strength and desirable metallurgical properties. Selecting appropriate fluxes, controlling flux density and thickness, and optimising welding parameters, weld joint design, filler materials, and heat treatment are crucial for achieving optimal results and addressing challenges associated with welding aerospace alloys. Additionally, the review highlights the significance of machine learning-based modelling and optimisation tools in fine-tuning A-TIG welding parameters to achieve superior metallurgical and mechanical properties, addressing challenges in aerospace alloy welding. © 2025 Elsevier B.V., All rights reserved.