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AM Al

The document discusses aluminum alloys used for welding, including both non-heat-treatable and heat-treatable alloys. It covers alloy designations and temper designations, as well as considerations for welding different alloys, such as filler metal selection and techniques to prevent issues like hot cracking and liquation cracking. Heat-treatable alloys generally require more careful welding due to multiple alloying elements and stronger base metals. Fine grain structures and low heat inputs can help address cracking challenges.

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Mahendra Sukre
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43 views

AM Al

The document discusses aluminum alloys used for welding, including both non-heat-treatable and heat-treatable alloys. It covers alloy designations and temper designations, as well as considerations for welding different alloys, such as filler metal selection and techniques to prevent issues like hot cracking and liquation cracking. Heat-treatable alloys generally require more careful welding due to multiple alloying elements and stronger base metals. Fine grain structures and low heat inputs can help address cracking challenges.

Uploaded by

Mahendra Sukre
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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AM-aluminum alloys

Non-Heat-Treatable Al Alloys
• Alloy Designation
• 1xxx: Pure aluminum (1050, 1200)
• 3xxx: Al-Mn (3003, 3005)
• 4xxx: Al-Si (4032, 4043)
• 5xxx: Al-Mg (5053, 5083)
• Temper Designation
• O : Annealed
• H : Cold worked
• H1(CW)
H18 (full hard) H16 (3/4 hard)
H14 (1/2 hard) H12 (1/4 hard)
• H2 (CW + partially annealed)
• H3 (CW + stabilization treatment)
Heat-Treatable Al Alloys
• Alloy Designation
– 2xxx: Al-Cu (2014, 2219, 2090 (contains Li))
– 6xxx: Al-Mg-Si (6061, 6262)
– 7xxx: Al-Zn-Mg (7020, 7075 (contains Cu))
• Temper Designation
– O : Annealed
– T : Thermally treated (T1 – T10)
– T3 (ST + CW + NA)
– T4 ( ST + NA)
– T6 ( ST + AG)
– T7 (ST + overaged)
– T8 ( ST + CW + AG)
Age Hardening
• Conditions
– Sloping solvus
– Coherency strains
• Strengthening depends
on Al-Cu phase diagram
– Coherency strains
– Precipitate Vol.%
– Size and distribution

Strengthening precipitates in Al 2219


Age Hardening
• Solution treatment
– Heat to dissolve all the
coarse second phase
particles
– Rapidly cool to achieve
supersaturation Prior to ST After ST After Aging
• Aging treatment
– Heat and soak to form
precipitates with desired
morphology
Peak aged
Hardness

Underaged Overaged
Time
Typical aging curve
Non-Heat-Treatable Al Alloys
Hot cracking is a not a serious issue

Base Filler
1xxx 1xxx (1100, 1188) and 4xxx (4043, 4047)
3xxx 1xxx, 3xxx, and 4xxx
4xxx 1xxx and 4xxx
5xxx 5xxx (5183, 5356, 5556) and 4xxx
(Low Mg) Caution: Mg2Si formation
5xxx 5xxx
(High Mg) Caution: Mg3Al2 network
Special considerations
Dissimilar welding or welding with dissimilar fillers: Dilution can result in a
susceptible weld composition
EBW or LBW: Loss of Mg can result in a susceptible weld composition
Heat-Treatable Al Alloys

• Serious hot cracking problems


– Multiple alloying elements
– Greater amounts of alloying additions
– Stronger base metals
• Solutions
– Non-heat-treatable Al alloy fillers
– Fillers with higher solute content (large volume of terminal liquid)
– Fusion zone grain refinement
Heat-Treatable Al Alloys – Filler Selection
Base metal Filler wire
Al-Cu (2219, 2014, (i) High-Cu fillers (2319) (corrosion problems)
2024) (ii) Al-Si (4043, 4047) and Al-Si-Cu (4145)
Al-Mg-Si (6061) (i) Al-Si (4043) (dilution < 50%)
(ii) Al-Mg (5356) (dilution < 30%)
Al-Zn-Mg (No Cu) (i) Al-Mg (5356, 5183)
(7005, 7020, 7039) (ii) Al-Si
(iii) Al-Zn-Mg (less Zn, more Mg)
Al-Zn-Mg (with Cu) Al-Si and Al-Mg fillers
(7075, 7178) Avoid welding in critical applications

Considerations: Hot cracking, strength, and corrosion


Some compromise on joint efficiency unavoidable
Grain Refinement
Fine, equiaxed structures are more resistant to hot cracking
Problem film formation less likely due to increased GB area
Popular techniques: Pulsing, MAO, and Inoculation

No inoculation With Ti

Al-Li alloy 2090 GTA welds (with 2319 filler)


Liquation Cracking
• Occurs in PMZ/HAZ
– Grain boundary melting
– Stresses
• Why more of a problem in Al
alloys?
– Wide PMZ (wide solidification
range and high K)
– Large shrinkage
– Large thermal contraction
(large CTE)

Al-Cu alloy 2219


Grain Boundary
Liquation
• Eutectic reaction
• Constitutional liquation
• Segregation
Liquation Cracking
Solutions
• Fine grained base metals Fine grains
• Low heat inputs and high energy density
processes
– Minimize HAZ/PMZ width
• Low melting fillers
– PMZ solidification precedes WM solidification

Coarse grains
Effect of BM grain size
on liquation cracking
HAZ in Al-Cu and Al-Mg-Si alloys
• HAZ response
– Base material type and
temper
– Precipitate formation,
coarsening, and
dissolution
• A portion of HAZ gets
overaged
– Post-weld aging further
overages
– ST + A required for
restoring HAZ properties
Thank You!

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