Double-pulse gas metal arc welding (DP-GMAW) is a common low-melting-point metal welding method. In this study, a low heat-input double-pulse gas metal arc welding (LHDP-GMAW) was proposed based on DP-GMAW. The welding process stability, weld bead shape, microstructure, and microhardness of 6061 aluminium alloy welding were analyzed for DP-GMAW and LHDP-GMAW with different low-frequency (3, 5 and 7 Hz). Compared with DP-GMAW, the stirring effect of alternating strong and weak pulses on the molten pool of LHDP-GMAW is enhanced and the heat input is reduced. Therefore, the LHDP-GMAW can produce more obvious fish-scale ripples, lower penetration, smaller and more uniform grains, and higher microhardness. This study provides a new solution for improving the welding quality of low-melting-point metal.
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