Effect of filler metals on solidification cracking susceptibility of Al alloys 2024 and 6061

Soysal, Tayfun; Kou, Sindo

doi:10.1016/j.jmatprotec.2018.11.022

Cited by 36 publications

(36 citation statements)

References 9 publications

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“…For example, Soysal et al [228] found that during gas tungsten arc welding of AA 2024, the use of a nonmatching filler material, AA 4145, greatly reduced cracking susceptibility of the base material. Here, the use of a filler material with a different composition from that of the original base material promotes a new solidification path that is less susceptible to cracking thus improving the joint mechanical properties.…”

Section: Use Of Grain Refiners or Filler Materials To Control The Micmentioning

confidence: 99%

Revisiting fundamental welding concepts to improve additive manufacturing: From theory to practice

Oliveira

Santos

Miranda

2020

Progress in Materials Science

422

134

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Additive manufacturing technologies based on melting and solidification have considerable similarities with fusion-based welding technologies, either by electric arc or high-power beams. However, several concepts are being introduced in additive manufacturing which have been extensively used in multipass arc welding with filler material. Therefore, clarification of fundamental definitions is important to establish a common background between welding and additive manufacturing research communities. This paper aims to review these concepts, highlighting the distinctive characteristics of fusion welding that can be embraced by additive manufacturing, namely the nature of rapid thermal cycles associated to small size and localized heat sources, the non-equilibrium nature of rapid solidification and its effects on: internal defects formation, phase transformations, residual stresses and distortions. Concerning process optimization, distinct criteria are proposed based on geometric, energetic and thermal considerations, allowing to determine an upper bound limit for the optimum hatch distance during additive manufacturing. Finally, a unified equation to compute the energy density is proposed. This equation enables to compare works performed with distinct equipment and experimental conditions, covering the major process parameters: power, travel speed, heat source dimension, hatch distance, deposited layer thickness and material grain size.

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Section: Use Of Grain Refiners or Filler Materials To Control The Micmentioning

confidence: 99%

Revisiting fundamental welding concepts to improve additive manufacturing: From theory to practice

Oliveira

Santos

Miranda

2020

Progress in Materials Science

422

134

View full text Add to dashboard Cite

show abstract

“…There are limited arc manipulation features and improving such technology is expensive [3]. Moreover, conventional fusion welding can result in occlusion of gases, porosity, slag inclusions, solidification cracks and other distortions, causing expensive reworks and usage of more materials [4]. Advancements in welding processes have, however, made it possible to produce sound joints using techniques such as solid-state welding, adaptive welding, robotic welding, cold metal transfer, spray arc, the use of flux cored welding wire, weld seam sensors and inverter-based power supplies.…”

Section: Introductionmentioning

confidence: 99%

Experimental Review on Friction Stir Welding of Aluminium Alloys with Nanoparticles

Vimalraj

Kah

2021

Metals

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To reduce environmental impacts and ensure competitiveness, the fabrication and construction sectors focus on minimizing energy and material usage, which leads to design requirements for complex structures by joining of similar and dissimilar materials. Meeting these industrial demands requires compatible materials with improved properties such as good weight-to-strength ratios, where aluminum (Al) and its alloys are competing candidates for various complex applications. However, joining Al with fusion welding processes leads to joint deterioration. Friction stir welding (FSW) produces joints at temperatures below the melting temperature, thus avoiding flaws associated with high heat input, yet requires improvement in the resultant joint properties. Recent studies have shown that nanoparticle reinforcement in FSW joints can improve weld properties. The main focus of this study is to critically review similar and dissimilar friction stir welding of AA5083 and AA6082 with carbide and oxide nanoparticle reinforcement. The study also discusses the effect of welding parameters on reinforcement particles and the effect of nanoparticle reinforcement on weld microstructure and properties, as well as development trends using nanoparticles in FSW. Analysis shows that friction stir welding parameters have a significant influence on the dispersion of the reinforcement nanoparticles, which contributes to determining the joint properties. Moreover, the distributed nanoparticles aid in grain refinement and improve joint properties. The type, amount and size of reinforcement nanoparticles together with the welding parameters significantly influence the joint properties and microstructures in similar and dissimilar Al welds. However, research is still required to determine the strengthening mechanism used by nanoparticles and to assess other nanoparticle additions in FSW of Al alloys.

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“…Cracks in metals, especially aluminum alloys, have been investigated for their effect on the mechanisms of fatigue crack initiation and propagation [12][13][14] and to understand the relationship between processing parameters and solidification cracks [15,16]. Lin et al [15] found that defects such as coarse secondary phases, welding porosities, and incomplete fusion can cause discontinuities such as cracks.…”

Section: Introductionmentioning

confidence: 99%

“…These discontinuities caused localized stress concentrators, which initiate fatigue cracks, accelerate the crack propagation rate, and eventually result in premature fracture at the weld zone (WZ). McCullough et al [16] employed and combined synergistic experimental and computational approaches to elucidate the underlying mechanisms of fatigue crack nucleation and crack propagation in AA6061-T6. It was demonstrated that the alloys AA6061-T6, in annealed conditions, failed in a similar number of cycles despite quantified differences in the cyclic stress-strain response.…”

Section: Introductionmentioning

confidence: 99%

“…It was demonstrated that the alloys AA6061-T6, in annealed conditions, failed in a similar number of cycles despite quantified differences in the cyclic stress-strain response. Soysal et al [16] studied the effect of fillers on the susceptibility to solidification cracking of AA2024. The filler metal ER4145 was highly effective against solidification cracking.…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

The Effect of Wire Feeding Speed on Solidification Cracking of CMT Welding for Al-Si Alloys

Huang

Chen

Konovalov

et al. 2021

Metals

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In this work, a welding solidification crack sensitivity test platform was established to study the effect of wire feeding speed (WFS) on solidification crack sensitivity during cold metal transfer (CMT) welding for AA6061 aluminum alloy. The test results show that as the WFS increased from 4 m/min to 5.5 m/min, the sensitivity of the solidification cracks also increased. With a further increase in the value of the WFS, the crack sensitivity decreased and eventually ceased to exist. A new perspective of the microstructure and crack propagation mechanics model was applied to understand the effect of WFS on solidification cracks. With the use of scanning electron microscopy (SEM) and a high-speed camera, it was found that as the WFS increased from 4 m/min to 5.5 m/min, the microstructure of the grain size changed from bigger to smaller, and the stability of the crystal microstructure was reduced. The crack propagation mechanics model was changed, which promotes crack propagation, increasing by 233%. When the WFS continued to increase beyond 5.5 m/min, the size of the crystal structure changed from small to big, the stability of the crystal microstructure was increased, the crack generation was suppressed, and the cracking rate was significantly reduced.

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Effect of filler metals on solidification cracking susceptibility of Al alloys 2024 and 6061

Cited by 36 publications

References 9 publications

Revisiting fundamental welding concepts to improve additive manufacturing: From theory to practice

Revisiting fundamental welding concepts to improve additive manufacturing: From theory to practice

Experimental Review on Friction Stir Welding of Aluminium Alloys with Nanoparticles

The Effect of Wire Feeding Speed on Solidification Cracking of CMT Welding for Al-Si Alloys

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