Weldability and Joining of Materials

Job knowledge21:
Aluminium Alloys
Aluminium and its alloys are used in fabrications because of their low weight,
good corrosion resistance and weldability. Although normally low strength, some
of the more complex alloys can have mechanical properties equivalent to steels.
The various types of aluminium alloy are identified and guidance is given on
fabricating components without impairing corrosion and mechanical properties of
the material or introducing imperfections into the weld.
Material types
As pure aluminium is relatively soft, small
amounts of alloying elements are added to
produce a range of mechanical properties. The
alloys are grouped according to the principal
alloying elements, Specific commercial alloys
have a four-digit designation according to the
international specifications for wrought alloys or
the ISO alpha - numeric system.
The alloys can be further classified according to
the means by which the alloying elements
develop mechanical properties, non-heat-
treatable or heat-treatable alloys.
Non-heat-treatable alloys
Material strength depends on the effect of work hardening and solid solution
hardening of alloy elements such as magnesium, and manganese; the alloying
elements are mainly found in the 1xxx, 3xxx and 5xxx series of alloys. When
welded, these alloys may lose the effects of work hardening which results in
softening of the HAZ adjacent to the weld.
Heat-treatable alloys
Material hardness and strength depend on alloy composition and heat treatment
(solution heat treatment and quenching followed by either natural or artificial
ageing produces a fine dispersion of the alloying constituents). Principal alloying
elements are defined in the 2xxx, 6xxx and 7xxx series. Fusion welding
redistributes the hardening constituents in the HAZ which locally reduces material
strength.
Processes
Most of the wrought grades in the 1xxx, 3xxx, 5xxx, 6xxx and medium strength
7xxx (e.g. 7020) series can be fusion welded using TIG, MIG and oxyfuel
processes. The 5xxx series alloys, in particular, have excellent weldability. High
strength alloys (e.g. 7010 and 7050) and most of the 2xxx series are not

recommended for fusion welding because they are prone to liquation and
solidification cracking.
The technique of Friction Stir Welding is particularly suited to aluminium alloys. It
is capable of producing sound welds in many alloys, including those heat treatable
alloys which are prone to hot cracking during fusion welding.
Filler alloys
Filler metal composition is determined by:
weldability of the parent metal
minimum mechanical properties of the weld metal
corrosion resistance
anodic coating requirements
Nominally matching filler metals are often employed for non-heat-treatable alloys.
However, for alloy-lean materials and heat-treatable alloys, non-matching fillers
are used to prevent solidification cracking.
The choice of filler metal composition for the various weldable alloys is specified in
BS EN 1011 Pt 4:2000 for TIG and MIG welding; recommended filler metal
compositions for the more commonly used alloys are given in the Table.
Alloy
Designation
Chemical
Designation
Classificati
on
Filler Application
EN AW-1080A EN AW-Al 99.8(A) NHT R-1080A Chemical plant
EN AW-3103 EN AW-Al Mn1 NHT R-3103 Buildings, heat exchangers
EN AW-4043A EN AW-Al Si5(A) - - Filler wire/rod
EN AW-5083
EN AW-Al
Mg4.5Mn0.7
NHT R-5556A Ships, rail wagons, bridges
EN AW-5251 EN AW-Al Mg2Mn0.3 NHT R-5356 Road vehicles, marine
EN AW-5356 EN AW-Al Mg5Cr(A) - - Filler wire/rod
EN AW-5556A EN AW-Al Mg5Mn - - Filer wire/rod
EN AW-6061 EN AW-Al Mg1SiCu HT
R-4043A
R-5356
Structural, pipes
EN AW-7020 EN AW-Al Zn4.5Mg1 HT R-5556A Structural, transport
HT = Heat treatable, NHT = Non Heat treatable
Imperfections in welds
Aluminium and its alloys can be readily welded providing appropriate precautions
are taken. The most likely imperfections in fusion welds are:

porosity
cracking
poor weld bead profile
Porosity
Porosity is often regarded as
an inherent feature of MIG
welds; typical appearance of
finely distributed porosity in
a TIG weld is shown in the
photograph. The main cause
of porosity is absorption of
hydrogen in the weld pool
which forms discrete pores in the solidifying weld metal. The most common
sources of hydrogen are hydrocarbons and moisture from contaminants on the
parent material and filler wire surfaces, and water vapour from the shielding gas
atmosphere. Even trace levels of hydrogen may exceed the threshold
concentration required to nucleate bubbles in the weld pool, aluminium being one
of the metals most susceptible to porosity.
To minimise the risk, rigorous cleaning of material surface and filler wire should
be carried out. Three cleaning techniques are suitable; mechanical cleaning,
solvent degreasing and chemical etch cleaning.
In gas shielded welding, air entrainment should be avoided by making sure there
is an efficient gas shield and the arc is protected from draughts. Precautions
should also be taken to avoid water vapour pickup from gas lines and welding
equipment; it is recommended that the welding system is purged for about an
hour before use.
Mechanical cleaning
Wire brushing (stainless steel bristles), scraping or filing can be used to remove
surface oxide and contaminants. Degreasing should be carried out before
mechanical cleaning.
Solvents
Dipping, spraying or wiping with organic solvents can be used to remove grease,
oil, dirt and loose particles.
Chemical etching
A solution of 5% sodium hydroxide can be used for batch cleaning but this should
be followed by rinsing in HNO
3
and water to remove reaction products on the
surface.
Solidification cracks
Cracking occurs in aluminium alloys
because of high stresses generated across

the weld due to the high thermal expansion ( twice that of steel) and the
substantial contraction on solidification - typically 5 % more than in equivalent
steel welds.
Solidification cracks form in the centre of the weld, usually extending along the
centreline during solidification. Solidification cracks also occur in the weld crater
at the end of the welding operation. The main causes of solidification cracks are
as follows:
incorrect filler wire/parent metal combination
incorrect weld geometry
welding under high restraint conditions
The cracking risk can be reduced by using a non-matching, crack-resistant filler
(usually from the 4xxx and 5xxx series alloys). The disadvantage is that the
resulting weld metal may have a lower strength than the parent metal and not
respond to a subsequent heat treatment. The weld bead must be thick enough to
withstand contraction stresses. Also, the degree of restraint on the weld can be
minimised by using correct edge preparation, accurate joint set up and correct
weld sequence.
Liquation cracking
Liquation cracking occurs in
the HAZ, when low melting
point films are formed at the
grain boundaries. These
cannot withstand the
contraction stresses
generated when the weld
metal solidifies and cools.
Heat treatable alloys,
particularly 6xxx and 7xxx
series alloys, are more
susceptible to this type of
cracking.
The risk can be reduced by
using a filler metal with a lower melting temperature than the parent metal, for
example the 6xxx series alloys are welded with a 4xxx filler metal. However, 4xxx
filler metal should not be used to weld high magnesium alloys (such as 5083) as
excessive magnesium-silicide may form at the fusion boundary decreasing
ductility and increasing crack sensitivity.

Poor weld bead profile
Incorrect welding parameter settings or poor welder technique can introduce weld
profile imperfections such as lack of fusion, lack of penetration and undercut. The
high thermal conductivity of aluminium and the rapidly solidifying weld pool make
these alloys particularly susceptible to profile imperfections.













































This Job Knowledge article was originally published in Connect, October 1996. It has
been updated so the web page no longer reflects exactly the printed version.
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