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Home > Education > Knowledge Center > Question and Answers > How to Avoid Cracking in Aluminum Alloys
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The most appropriate and successful method used to prevent cracking in the 6xxx series base materials is to ensure adequate filler alloy is added during the welding operation. Other considerations when welding this group of alloys (6xxx) are the effect of joint design on base alloy and filler alloy dilution as well as the weld profile relating to susceptibility to cracking. Square groove welds in this material are extremely vulnerable to cracking because very little filler alloy mixes with the base material during welding. It is frequently necessary to evaluate the use of a v-groove weld preparation, which will introduce more filler alloy to the weld metal mixture and lower the crack sensitivity. In addition, concaved fillet welds that have reduced throat thickness and concaved root passes in butt welds may have a tendency to crack (see fig 3). Further Considerations The crack sensitivity curves provides an excellent guide to the probability of hot cracking, however, there are other issues to consider in order to understand cracking in aluminum alloys. One of these issues is the effect of alloying elements other than the principal alloying elements addressed in the crack sensitivity curves. Most certainly, some aluminum base alloys can be difficult to weld and lead to cracking problems, especially without complete understanding of their properties and/or if inappropriately handled. In fact, some aluminum base alloys are unsuitable for arc welding, and for this reason they are usually joined mechanically by riveting or bolting. These aluminum alloys can be difficult to arc weld without encountering problems during and/or after welding. These problems are usually associated with cracking, most often, hot cracking and on occasion, stress corrosion cracking (SCC). The aluminum alloys that fall into this difficult-to-weld category can be divided into different groups. Always be aware of the small selection of aluminum alloys designed for machineability, not weldability. Such alloys are 2011 and 6262, which contain 0.20-0.6, Bi, 0.20-0.6 Pb and 0.40-0.7 Bi, 0.40-0.7 Pb, respectively. The addition of the elements (Bismuth and Lead) to these materials provides excellent chip formation in these free machining alloys. However, because of their low solidification temperatures, they can seriously reduce the ability to produce sound welds in these materials. In addition to the free machining alloys referenced above, many other aluminum alloys can be quite susceptible to hot cracking if arc welded. These alloys are usually heat treatable and are most commonly found in the 2xxx series (Al-Cu), and 7xxx series (Al-Zn) groups of materials,. To understand why some of these alloys are unsuitable for arc welding, it is necessary to consider the reasons why some aluminum alloys can be more susceptible to hot cracking. Hot cracking, or solidification cracking, occurs in aluminum welds when high levels of thermal stress and solidification shrinkage are present while the weld is undergoing various degrees of solidification. A combination of mechanical, thermal and metallurgical factors influence the hot cracking sensitivity of any aluminum alloy. By combining various alloying elements, many high-performance, heat treatable aluminum alloys have been developed to improve the materials mechanical properties. In some cases, the combination of the required alloying elements has produced materials with high hot cracking sensitivity. Coherence Range Perhaps the most important factor affecting the hot crack sensitivity of aluminum welds is the temperature range of dendrite coherence and the type and amount of liquid available during the freezing process. Coherence occurs when the dendrites begin to inter-lock with one another so that the melted material begins to form a mushy stage. The coherence range is the temperature between the formation of coherent interlocking dendrites and the solidus temperature. The wider the coherence range, the more likely hot cracking will occur due to the accumulating strain of solidification between the interlocking dendrites. The 2xxx Series Alloys (Al-Cu) Hot cracking sensitivity increases in the Al-Cu alloys when adding approximately 3% Cu; however, it then decreases to a relatively low level at 4.5% Cu and above. Alloy 2219 with 6.3% Cu shows good resistance to hot cracking because of its relatively narrow coherence range. Alloy 2024 contains approximately 4.5% Cu causing the perception of having relatively low crack sensitivity. However, alloy 2024 also contains a small amount of Magnesium (Mg). The small amount of Mg in this alloy depresses the solidus temperature, but it does not affect the coherence temperature; therefore, the coherence range extends and the hot cracking tendency increases. The problem when welding 2024 is that the heat of the welding operation will allow segregation of the alloying constituents at the grain boundaries, and the presence of Mg, as stated above, will depress the solidus temperature. Because these alloying constituents have lower melting phases, the stress of solidification may cause cracking at the grain boundaries and/or establish the condition within the material conducive to stress corrosion cracking later. High heat input during welding, repeated weld passes, and larger weld sizes can all increase the grain boundary segregation problem (segregation is a time-temperature relationship) and subsequent cracking tendency. The 7xxx Series Alloys (Al-Zn) The 7xxx series of alloys, when considering weldability, contain two separate groups: the Al-Zn-Mg and the Al-Zn-Mg-Cu types. Al-Zn-Mg Alloys such as 7005 will resist hot cracking better and exhibit superior joint performance than the Al-Zn-Mg-Cu alloys such as 7075. The Mg content in this group (Al-Zn-Mg) of alloys would normally increase the cracking sensitivity. However, adding Zr to refine grain size effectively reduces the cracking tendency. This alloy group welds easily with the high magnesium filler alloys such as 5356, which ensures the weld contains sufficient magnesium to prevent cracking. The recommendation of silicon-based filler alloys, such as 4043, for these alloys is not desirable because the excess Si introduced by the filler alloy can result in the formation of excessive amounts of brittle Mg2Si particles in the weld. Al-Zn-Mg-Cu Alloys such as 7075 have small amounts of Cu added. The small amounts of Cu, along with the Mg, extend the coherence range and, therefore, increase the crack sensitivity. A similar situation can occur with these materials as with the 2024 type alloys.
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The stress of solidification may cause cracking at the grain boundaries and/or establish the condition within the material conducive to stress corrosion cracking later. Be Aware: The problem of higher susceptibility to hot cracking from increasing the coherence range is not only confined to the welding of these more susceptible base alloys, such as 2024 and 7075. Crack sensitivity can be substantially increased when welding incompatible dissimilar base alloys (which are normally easily welded to themselves) and/or through the selection of an incompatible filler alloy. For example, by joining a perfectly weldable 2xxx series base alloy to a perfectly weldable 5xxx series base alloy, or by using a 5xxx series filler alloy to weld a 2xxx series base alloy, or a 2xxx series filler alloy on a 5xxx series base alloy, we can create the same scenario. If we mix high Cu and high Mg during the welding operation, we can extend the coherence range and, therefore, increase the crack sensitivity. Summary: Avoid hot cracking in aluminum alloys by applying one or more of the following appropriate principals:
Avoid the extremely crack sensitive base materials that are generally accepted as being non-weldable. Use a suitable filler alloy selection chart for selecting the most appropriate filler alloy for the specific base alloy, thereby avoiding the critical chemistry ranges (crack sensitivity ranges) in the weld. Select a filler alloy with a solidification point close to or below that of the base material. Select the most appropriate edge preparation and root gap to permit sufficient filler alloy material addition thus creating a weld metal chemistry outside the critical chemistry range. To counteract cracking problems, use reputable filler alloys that have grain refiners added, such as titanium or zirconium. Use the highest welding speed possible. The faster the weld is conducted, the faster the cooling rate and the less time the weld is in the hot cracking temperature range. Try to use welding and assembly sequences and techniques that minimize restraint, reduce residual stress and produce welds of acceptable profile. Apply a compressive force on the welded joint during welding to counteract the cracking mechanism.
Fig 1. This figure shows the effects of four different alloy additions on the crack sensitivity of aluminum
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Fig 2 Here are two GTAW (TIG) welds side by side made on a 6061-T6 base plate. 1. The top weld was deposited with no filler alloy, and then subjected to liquid penetrant testing. The testing method revealed many fine linear indications (cracks) within the surface of the weld. 2. The lower weld conducted also without filler alloy, used a higher current and slower travel speed. The excessive heat input during the welding of this bead has developed far more stress across the weld, resulting in a much more obvious cracking situation. As can easily be seen, without liquid penetrant testing, a large longitudinal crack has developed down the center of the weld bead.
The conclusion is that hot cracking of one form or another can be expected if the 6xxx series base alloys are welded without the addition of filler material.
Fig 3. This picture shows two fillet weld terminations in the corner of a welded structure. Cracking is visible in both termination craters. Also cracking is visible along the center of both welds. The reason for this hot cracking is undesirable weld profile caused by poor welding technique. The reduction in throat thickness at the termination and for a portion of the fillet weld has allowed the stresses developed during welding to fracture the weld.
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