<![CDATA[While Tungsten Inert Gas (TIG) welding is renowned for its precision, its limited depth of penetration often restricts its application for thicker substrates. This study evaluates the efficacy of Activated TIG (A-TIG) welding in enhancing the depth of penetration of 5083 aluminum alloy plates using a square butt joint configuration. Two oxide active fluxes, SiO2 and ZnO, were tested across varying welding currents, 100 A, 130 A, and 160 A. Cross-sectional macrostructural analysis revealed that SiO2 active flux at 160 A achieved the maximum depth of penetration of 4.73 mm, whereas ZnO active flux at 100 A yielded the minimum depth of penetration of 3.1 mm. The depth of penetration of SiO2 active flux increased about 52.6% over ZnO. While the base metal remained microstructurally stable, the Heat Affected Zone (HAZ) and weld metal exhibited a proliferation of Mg2Si particles correlated with increased heat input. Conversely, Vickers hardness testing indicated that ZnO at 100 A produced the highest hardness of 71.85 kgf/mm2, while SiO2 at 160 A resulted in the lowest of 53.26 kgf/mm2. However, elevated heat inputs expanded Mg2Si precipitation in the heat-affected zone, driving a 25.9% reduction in hardness. Quantifying this penetration-hardness trade-off provides marine fabricators with an operational framework, SiO2 at higher currents for full-penetration single-pass welds, or ZnO at lower currents to maximize joint strength.]]>
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