Dr.R.SIVASANKARI ASSISTANT PROFESSOR DEPARTMENT OF METALLURGICAL ENGINEERING PSG COLLEGE OF TECHNOLOGY COIMBATORE ALUMINIUM ALLOYS CHARACTERISTICS THAT INFLUENCE WELDABILITY
• Formation of refractory oxide
• High thermal conductivity • High thermal expansion • Hydrogen solubility: High in liquid state Low in solid state • Sensitivity to Hot cracking TWO MAIN GROUPS
• Heat treatable alloys
Strengthening by precipitation hardening
• Non heat-treatable alloys
Strengthening by cold working only Heat treatable alloys
• 2XXX Al-Cu, Al-Cu-Mg, Al-Cu-Li
• 6XXX Al-Mg-Si
• 7XXX Al-Zn, Al-Zn-Mg, Al-Zn-Mg-Cu
• 8XXX Al-Li-Cu-Mg Non heat-treatable alloys • 1XXX Pure Al
Quenching Aging Al-Cu Alloy system Problems in welding of Heat treatable alloys
• Hot cracking • Porosity • HAZ degradation • Oxide formation • High thermal conductivity HOT CRACKING
• Greater amounts of alloying –
Wider solidification temperature range
• Large change in volume upon solidification
• High thermal expansion
SOLIDIFICATION CRACKING
• Weld zone • Along centre of weld / termination centres • Factors: • Degree of restraint • Weld metal composition – especially though filler metal • Heat input - high heat input promotes cracking Relative cracking sensitivity LIQUATION CRACKING • At PMZ, due to large amount of alloying
• Formation of eutectics / low melting constituents at grain
boundaries
• Higher heat input widens PMZ
• Low melting fillers provide less susceptibility
• Solidification shrinkage stresses at low temperature
• Solidification of PMZ to occur prior to solidification shrinkage
stresses Porosity
Hydrogen solubility in Al • Excess hydrogen forms pores.
• Pore’s buoyancy velocity should be more than
velocity of solidifying front.
• Lower welding speeds create slower
solidification fronts. PRECIPITATION HARDENED ALLOY WELDED IN FULL HARD CONDITION HAZ Degradation OXIDE FORMATION ON SURFACE
• Strong chemical affinity for oxygen
• Accelerated by thermal treatment and moist
atmosphere
• Melting point of Al2O3: 20500C
• Improper fusion
• Prevents arc initiation
OXIDE REMOVAL • Thicker oxides by chemical / mechanical means
• Self cleaning by appropriate polarity
FILLER ALLOY SELECTION • Fillers with high amount of solute
• Lower melting point – formation of eutectic liquid
• Low melting constituents of base metal to
solidify before weld metal
• Adequate dilution of filler is necessary
Problems in welding of Non-heat treatable Al alloys
• Hot cracking – some times occurs.
But not so severe.
• Porosity
• HAZ degradation HAZ degradation
• Limited to recovery, recrystallisation and grain
growth
• Weld metal is the weakest zone
• First HAZ is fully annealed.
Work hardening effect will be removed. NICKEL ALLOYS Nickel Alloys • FCC • No phase transformation • Similar in many respects to the austenitic stainless steels • Coeff. of Thermal. Expn. < Stainless steel • Distortion control measures are similar to Carbon steel • Applications – high temperature oxidation and creep resistance – aggressive corrosive environments – very low temperature cryogenic applications. • 2 families of alloys – solid solution strengthened alloys – precipitation hardened alloys. Common Ni alloys Alloy 200 CP 99.2Ni Monel/Alloy 400 SS 68Ni-33Cu Monel/Alloy K500 PH 65Ni-3Al-0.5Ti-32Cu Alloy 600 SS 75Ni-15Cr-8Fe Alloy 617 SS 46Ni-22Cr-9Mo-12Co Alloy 625 SS 64Ni-22Cr-8Mo-3Fe-4Nb Alloy 718 PH 52Ni-19Cr-3Mo-5Nb Alloy 800 SS 32Ni-22Cr-42Fe- Alloy 825 SS 42Ni-22Cr-28Fe-2Cu Nimonic PH 44Ni-16Cr-3Mo-29Fe METALLURGICAL DIFFICULTIES
• Hot cracking in weld metal or PMZ
Source of problem: S P, Pb, Bi, B also contribute. Contamination by grease, oil, dirt, etc. • Machining / stainless steel wire brushing followed by degreasing is necessary prior to welding. • Any heat treatment must be carried out using S - free fuel or by using electric furnaces. METALLURGICAL DIFFICULTIES
• Porosity due to Nitrogen.
• As little as 0.025% nitrogen can form pores in the solidifying WM
• Quite light draughts can disrupt the gas shield and cause porosity.
• Use good shield, particularly in site welding applications.
• Use good gas purity and efficiency of the gas shield
• Oxygen can also cause of porosity, when it combines with carbon in
the weld pool to form carbon monoxide. Use sufficient deoxidants. METALLURGICAL DIFFICULTIES
• Sluggish weld pool - does not flow freely
• Lumpy and convex weld bead METALLURGICAL DIFFICULTIES • Wrought, fine grained components have better weldability than cast items as these often have significant amounts of segregation.
• Coarse grains may lead to micro-fissuring in the HAZ
thus high heat input is best avoided. All the alloys are best welded in the annealed or solution treated condition WELDABILITY TEST
Y-GROOVE TEKKEN TEST
60º
2 mm COLD CRACKING TEST IMPLANT TESTING
implant specimens
Implant testing machine
IMPLANT TEST
Implant specimen Base plate for implant test IMPLANT TEST HOULDCROFT TEST - SELF RESTRAINT TEST VARESTRAINT TEST VARESTRAINT TEST VARESTRAINT TEST 12.5 25
125
Thickness: 3 mm All dimensions are in mm Varestraint specimen dimensions VARESTRAINT TEST RESULT
Oxy-Acetylene Welding and Cutting
Electric, Forge and Thermit Welding together with related methods and materials used in metal working and the oxygen process for removal of carbon
Oxy-Acetylene Welding and Cutting
Electric, Forge and Thermit Welding together with related methods and materials used in metal working and the oxygen process for removal of carbon
