The mechanical properties of repair welding of aluminum alloy 6082-T6 welded with 5356 filler metal were studied using pulsed metal inert gas (MIG) welding process at frequencies of 1.5 Hz and 5 Hz. The effect of pulse current frequencies on their mechanical properties of welded samples was investigated by analyzing macrostructure, microstructure, the density of porosity, and mechanical tests such as tensile, bending and hardness tests. Experimental results showed that repeated heat input and porosity in weld metal contributed to poor mechanical resistance. It was found that increasing the frequency has a beneficial effect on reducing the amount of porosity as well as the size of pores in the welded samples, giving superior mechanical properties. The repair weld welded using high pulse current frequency provided higher tensile strength and superior bending resistance, suggesting that the high pulsed MIG welding is preferable for repair welding of Al 6082-T6.
