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- Hydrogen desorption (4)
- Solidification cracking (4)
- Titanium alloys (4)
- Corrosion behavior (3)
- Microstructure (3)
- Solidification Cracking (3)
- 6060 aluminium (2)
- AZ31 Magnesium Alloy (2)
- AZ31B (2)
- Aluminium alloy (2)
Al-Mg-Si alloys are known to be highly susceptible to solidification cracking except when using an appropriate filler metal (e.g., 4343 or 5356), although the amount of dilution required to avoid cracking has never been a well-defined quantity. The aim of the present study is to determine a relationship between filler metal dilution, local strain rate conditions, and cracking susceptibility. Making use of the controlled tensile weldability (CTW) test and local strain extensometer measurements, a boundary has been established between crack and non-crack conditions for different local strain rates and dilution amounts, holding all other welding parameters constant. This boundary, presented in the form of critical strain rate-dilution map, defines the critical amount of 4043 filler metal required to avoid solidification cracking when arc welding 6060 aluminium, depending upon local strain rate.
Earlier work has established that a critical amount of 4043 filler is required to avoid solidification cracking when arc-welding 6060 aluminium, depending upon local strain conditions. For example, when the mushy zone behind the weld pool experiences a tensile strain from combined thermal and shrinkage stresses, the possibility exists for crack initiation. For a greater rate of strain, it has been determined that a greater 4043 dilution (i.e. higher weld metal silicon content) is required to avoid crack initiation. Making use of the Controlled Tensile Weldability (CTW) test and local strain extensometer measurements, a boundary has been established between crack and no-crack conditions for different local strain rates and filler dilutions, holding all other welding parameters constant. Using this established boundary as a line of reference, additional parameters have now been examined and their influence on cracking has been characterized. These parameter influences have included studies of weld travel speed, weld pool contaminants (Fe, O, and H), and grain refiner additions (TiAl3 + Boron). Each parameter has been independently varied and its effect on cracking susceptibility quantified in terms of a critical strain rate required to initiate cracking for a given 4043 filler dilution.
A perspective will be given that outlines important considerations in evaluating and predicting weldability. An examination will be made of the local conditions necessary for solidifications crack initiation and growth in a weld. This will be done in light of two prominent thermo-mechanical approaches involving critical strain and critical strain rate. Critical conditions will be identified based upon values available in the literature. Methods used to measure strain and strain rate will be compared. The interpretation of crack lenght measurements commonly used to quantify weldability will be questioned, based upon our current understanding of the problem. Complications and problem areas needing better definition will be identified and discussed, including strain distribution in the mushy zone, segregation at grain boundaries, effect of impurities, and effect of cooling rate on solidification path. Finally, a suggestion will be made for a new approach to weld development using in-situ strain rate measurements and new composition-strain rate maps that define the boundary between crack an no-crack conditions.
Aluminium alloy 6060 is typical of a family of Al-Mg-Si extrusion alloys, which are considered weldable only
when using an appropriate filler alloy such as 4043 (Al-5Si) or 5356 (Al-5Mg). This study concerns the
thermal analysis and solidification path determination of aluminium alloy 6060 diluted with variable amounts
of 4043. Casting of controlled mixtures of alloys 6060 and 4043 was used to simulate different weld dilutions
in order to facilitate thermal analysis. Thermal analysis and metallography were applied in order to reveal
solidification reactions and phases, and allow calculation of solid fraction versus temperature curves.
Although the liquidus temperature was little affected, different phases formed with increased 4043 dilution,
with a trend toward lower temperature reactions and a larger fraction interdendritic constituent.
Different characteristics of hydrogen's absorption/desorption behavior and trapping in ß-21S titanium alloy are studied by means of thermal desorption spectroscopy (TDS). Spectra analysis is supported by data from variety of other experimental techniques, such as LECO hydrogen determinator, XRD and microstructure investigations by means of optic and electronic microscopy. In contrast to many past considerations, the complex process of hydrogen evolution has been found to be significantly affected by the way hydrogen introduction into the alloy. The different trapping sites, as well as phase transformations, have to be considered as the reasons for the different hydrogen evolution behavior.
Gas tungsten arc welds made on wrought magnesium AZ31 plate have
been characterized for corrosion in saline solution (3.5% NaCl). Microstructural
changes induced by the welding process resulted in different
environmental behaviour of each zone (BM-base metal, HAZ-heat affected
zone and FZ-fusion zone). The faster kinetics of corrosion in FZ and especially
HAZ are attributed to (a) the coarse microstructure, consisting of
large grains, and (b) very small amounts of ß-phase in the grain boundaries.
Also, hardness traverses have shown that these zones are weaker
than the base metal. Based on the significant effect of grain size on strength
in magnesium alloys, the weld metal grains have been systematically refined
using controlled oscillation during welding, and by adding a grain
refiner to the weld pool. Detailed microstructure analyses have been carried
out and the relationships between corrosion behaviour, mechanical
properties and microstructure (grain refinement and second-phases formation)
are highlighted.
Based on its excellent combination of a high strength/weight ratio and good corrosion behavior, Ti6Al4V alloy is ranked among the most important advanced materials for a variety of industrial applications. However, in many of these technological applications, this alloy is exposed to environments which can act as sources of hydrogen, and severe problems may arise based on its susceptibility to hydrogen embrittlement. Even small hydrogen concentrations might lead to failure. Consequently, a comprehensive knowledge of hydrogen's absorption/desorption behavior and interactions between hydrogen and different microstructural features is necessary to better understand the desorption and trapping mechanisms, the types of the trap sites, and the trapped hydrogen content, in order to determine the safe service conditions of this alloy in the industry. In this paper, different characteristics of hydrogen's absorption/desorption behavior and trapping in a duplex-annealed Ti6Al4V alloy are studied by means of thermal desorption spectroscopy (TDS). Spectra analysis is supported by data from a variety of other experimental techniques, such as LECO hydrogen determinator, XRD and microstructure investigations by means of optical and electron microscopy. Hydrogen evolution is found to be a very complex process, being affected by the way hydrogen was initially introduced to the alloy, the phase transformations that may occur during the thermal analysis and the presence of potential trapping sites.
The relation between microstructure and corrosion behavior of GTA welded AZ31B magnesium sheet
(2007)
Welding of AZ31B magnesium alloy was carried out using gas-tungsten arc (GTA) welding. The microstructure and the corrosion behavior of welded magnesium AZ31B alloy were investigated. ac and dc polarization tests were carried out on the welded Mg sheet. The microstructure was examined using optical and electron microscopy (TEM and SEM), X-ray analysis and EDS. Scanning Kelvin probe force microscopy (SKPFM) was used in order to measure the Volta potential of different phases relative to the matrix. The results showed that the GTA process effected both the microstructure and the corrosion behavior. These results can be explained by the effects of the process on microstructure of AZ31B Mg alloy sheet such as grain size and precipitates caused by the change in precipitation and recrystallization behavior.
Weld metal microstructure for alloy 6060 aluminum welds, made using the gas-tungsten arc process and alloy 4043 filler metal, has been characterized using optical metallography, EPMA microprobe analysis, SEM/EBSD and STEM/EDX electron microscopy, and single-sensor differential thermal analysis (SS-DTA). In addition, alloy 6060 castings were solidified at variable cooling rates approaching that of welding, to provide a reference for comparison with weld microstructure. It was found that a major change in cast microstructure occurs at cooling rates higher than 27 K/s resulting in a structure similar to that observed in weld metal. Rapid cooling is believed to favor low temperature solidification reactions that normally would be achieved only at higher silicon content. Accordingly, additions of 4043 filler metal that increase the weld metal silicon content have only limited affect on weld solidification range and microstructure. This has direct implications regarding how 4043 filler additions improve weldability and weld quality.
In the present work, mechanisms are proposed for solidification crack initiation and growth in aluminum alloy 6060 arc welds. Calculations for an interdendritic liquid pressure drop, made using the Rappaz-Drezet-Gremaud (RDG) model, demonstrate that cavitation as a liquid fracture mechanism is not likely to occur except at elevated levels of hydrogen content. Instead, a porosity-based crack initiation model has been developed based upon pore stability criteria, assuming that gas pores expand from pre-existing nuclei. Crack initiation is taken to occur when stable pores form within the coherent dendrite region, depending upon hydrogen content. Following initiation, crack growth is modeled using a mass balance approach, controlled by local strain rate conditions. The critical grain boundary liquid deformation rate needed for solidification crack growth has been determined for a weld made with a 16 pct 4043 filler addition, based upon the local strain rate measurement and a simplified strain rate partitioning model. Combined models show that hydrogen and strain rate control crack initiation and growth, respectively. A hypothetical hydrogen strain rate map is presented, defining conceptually the combined conditions needed for cracking and porosity.
The occurrence of solidification cracking during welding remains a little understood phenomenon, in spite of extensive studies and tests performed to evaluate and compare the relative weldability of many different alloys. From an approach often adopted in the welding community attributed to Prokhorov, solidification cracks are believed to form when a critical tensile strain is exceeded, specific to the alloy, assuming that the mushy-zone has limited ductility. Tensile stresses and strains normally form behind a moving weld pool as a result of solidification shrinkage and thermal contraction, as influenced by welding parameters and the degree of restraint.
Grain refinement is an important possibility to enhance the weldability of aluminium weld metal that is usually defined by its susceptibility to solidification cracking. In this study, grain refinement was achieved through the addition of commercial grain refiner containing titanium and boron to the GTA weld metal of aluminium alloy 6082. The weld metal mean grain size could be reduced significantly from about 70 µm to a saturated size of 21 µm with a change in grain shape from columnar to equiaxed. The grain refinement prevented the formation of centreline solidification cracking that was present only in welds with unrefined grain structure. A variation of torch speed led to a strong change of solidification parameters such as cooling rate that was measured in the weld metal and the corresponding solidification rate and thermal gradient. The ratio thermal gradient/growth rate (G/R) decreased from 50 K s/mm² (high torch speed) to 10 K s/mm² (low torch speed). However, the variation of torch speed did not change the tendency for solidification cracking. The microstructure of unrefined and completely refined weld metal was compared. The observed change in size and distribution of the interdendritic phases was related to the change in susceptibility to solidification cracking.
AZ31 Mg alloy sheet was welded using a gas-tungsten arc (GTA) process over inserts containing 2.3-9.3 wt.% Al. The welded specimens were susceptible to SCC in distilled water, with susceptibility increasing with decreasing weld metal Al (or β particle) concentration. Primary stress corrosion cracks initiated at the weld metal-HAZ interface by stress-assisted localised dissolution and propagated through the weld and base metals by transgranular and intergranular H-assisted fracture (TG-HAF and IG-HAF) respectively. The IG fracture mode may be intrinsic to the texture imparted upon the base metal by rolling. The increase in SCC susceptibility with decreasing weld metal Al concentration is contrary to the purported roles of β particles in promoting localised corrosion and as crack nucleation sites, but corresponds with increases in weld - base metal galvanic current density and weld metal localised corrosion susceptibility.