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When Welding
Aluminum Alloys
By:
Porosity
Incomplete Fusion
Causes
&
Correction
Incomplete Penetration
Problem Solving
On the low alloy content side there is only a small amount of eutectic
present which results in the liquid film on the grain boundaries being
discontinuous or very thin Low crack sensitivity - 1
As the liquid film thickness increases the force required to tear the film
reduces and crack sensitivity increases High crack sensitivity - 2
Once there is sufficient eutectic available it can begin to flow into and fill
any cracks that form Low crack sensitivity - 3
2
Hot Cracking
All aluminum alloys are susceptible
to some degree of hot cracking,
differing only in their degree of
susceptibility
Cracking tests have been used to
determine the range of composition
within which an alloy has a high risk
of hot cracking
Problem Solving
Crack Sensitivity
0
Al - Cu
0
Al - Mg
0
Al - Mg2 Si
0
1
Weld on the
right is welded
without filler
metal
(autogenous)
and we see a
large centerline
crack
Visual Inspection of two welds made with the GTAW process on base metal 6061-T6
Crack Sensitivity
0
Al - Cu
0
Al - Mg
0
Al - Mg2 Si
0
1
6061 Base Metal has Mg2Si Content Around Maximum Crack Sensitivity
Al - Mg2 Si
0
1
Weld B on the same base material welded with 4043 filler metal has no cracking
WHY?
The 4043 filler metal provides a number of characteristics that help to prevent cracking
when welding the 6xxx series alloys:
It combines with the base metal which lowers the percentage of Mg2Si in the
solidifying weld and thereby reduces crack sensitivity
It has a lower solidification temperature which allows the base metal to solidify
prior to the weld
The addition of higher percentages of silicon to the solidifying weld metal
decreases the total shrinkage during freezing
Single-v-groove weld
Crack Sensitivity
0
Al - Cu
0
Al - Mg
0
Al - Mg2 Si
0
1
1.8% Mg
3.4% Mg
Al - Mg
0
Composition Of Weld - Percent Alloying Element
60%
Filler
Metal
40%
Base
Metal
Crack
6061-T6
Base Metal
Fillet Weld
Crater Crack
AWS D1.2 2008 Structural Welding Code (4.17) Terminating a weld within a
joint may be done by any of the following methods or combination thereof:
Reversing the direction of travel for a distance of at least 2 in [50 mm]
Increasing travel speed
Providing a build-up of metal and remolding the crater area flush with the weld
surface by mechanical means
Using automated crater fill features in the welding equipment
Rapidly triggering the gun manually as the weld is terminated
Note: The Specification addresses these alloys in both the H116 & H321 tempers
Fig c and d
Show examples
of an
Intergranular
attack and are
examples of
material that
would fail
specification
ASTM B 928
The Weld Meal Properties Used To Select The Most Appropriate Filler Metal
Crack Sensitivity
Elevated Temperature Service
Strength
Color Match After Anodizing
Ductility
Post Weld Heat Treatment
Corrosion Resistance
Toughness
(Hobart Aluminum Brochure 3 Page fold-out at back of brochure)