D. F. Farson, J. Menke, N. Chantarat, T. Allen, Ohio State University, Columbus, OH; B. Green, EWI, columbus, OH

Summary: In this research, a variable polarity GTAW process was optimized for porosity-free welding of Aluminum tubing. The welding parameters were varied according to a designed experiment and the results were analyzed to determine the optimum settings. In addition, a numerical simulation of the process to optimize the heat input so as to obtain consistent penetration profile around the tube and in the weld overlap area.