Mathematical models have been developed to predict the tensile strength and impact toughness of Pulsed TIG (Tungsten Inert Gas) welded Al-Mg-Si (AA 6061) alloys with the addition of AA 4043 (Al-5%Si) filler metal. The design of experiments (DoE) concept has been used to optimize the required number of experiments. Pulsed Current (PC) welding parameters such as Peak Current, Base Current, Pulse Frequency and Pulse on Time have been chosen as the important factors. Tensile strength of the joints has been evaluated using UTM. The models have been developed by use of the Response Surface Method (RSM). Analysis of Variance (ANOVA) technique has been applied to find the significant factors. The adequacy of the developed models has been checked by calculating correlation coefficient. The influences of pulsed current parameters on tensile strength and impact toughness have been analysed in detail.
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