Gas-Tungsten Arc Welding of Dissimilar Aluminum Alloys With Nano-Treated Filler

Murali, Narayanan; Sokoluk, Maximilian; Yao, Gongcheng; Pan, Shuaihang; Rosa, Igor M. De; Li, Xiaochun

doi:10.1115/1.4049849

Cited by 16 publications

(7 citation statements)

References 33 publications

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“…Hot cracks start from perpendicular tensile stresses exerted by solidification-induced contraction of primary grains without compensatory, intergranular WM liquid; these are especially problematic if the mechanism behind their nucleation and propagation is not circumvented. However, nano-treating accomplishes this [15] by enabling the formation of a fine, equiaxed grain structure; this prevents liquid blockage in the microstructure and the subsequent formation of defects that can potentially start a hot crack while allowing the microstructure to withstand thermal shrinkage stresses. It is also noteworthy that the use of nanoparticles can eliminate commonly observed grain size gradients in the WM [16] by homogenising grain growth from the interface.…”

Section: Weld Microstructuresmentioning

confidence: 99%

“…Oropeza, et al used the nano-treated AA7075 to both weld AA7075 and fabricate a multi-layer part using wire-based additive manufacturing and achieved similar trends in microstructure and mechanical performance [13]. Murali, et al used nano-treated ER5183 filler to weld AA2024, AA5083, AA6061, and AA7075 [14] as well as two dissimilar systems of AA2024/AA5083 and AA2024/AA7075 [15] to highlight the broad applicability of nano-treating to the welding process. A third dissimilar system of AA6061/AA7075 was joined with two nano-treated fillers to show how matching the filler's composition to a base metal could benefit mechanical properties [16].…”

Section: Introductionmentioning

confidence: 99%

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Natural aging of heterogeneous arc-welded AA6061-AA7075 joints with nanocomposite filler

Murali

Zheng

Chi

et al. 2023

Science and Technology of Welding and Joining

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We report the dissimilar joining of aluminium alloys 6061 and 7075 using filler rods nano-treated with TiC nanoparticles. TiC enables the formation of a fine and equiaxial weld metal microstructure while preventing the formation of hot cracks. Dissimilar joints were also naturally aged, and their strength evolutions were tracked over 8 weeks and compared to a nano-treated, homogeneous AA7075 joint. Heterogeneous weld metals regained over 30 HV with a mix of MgZn 2 and Mg 2 Si strengthening phases. Nano-treatment thus shows great promise, being able to facilitate the fusion welding of a traditionally difficult-to-weld system and enable a natural aging response between two artificially aged alloys.

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Section: Weld Microstructuresmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Natural aging of heterogeneous arc-welded AA6061-AA7075 joints with nanocomposite filler

Murali

Zheng

Chi

et al. 2023

Science and Technology of Welding and Joining

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“…As mentioned earlier in the introduction section, WAAM process depends on traditional welding arc processes, thus unweldable alloys such as Al-Zn-Mg-Cu [127], AA7075 [128], AA7055 [129], AA2024 [130], and super alloys with overall Al and Ti content of more than 6% [131] are highly restricted due to their hot crack sensitivity behavior during a fusion weld process. Therefore, alloys attracted to hot cracking such the mentioned ones are unrecommended in WAAM due to their predisposition and ability of forming hot cracking at some point in the process and producing of unacceptable part.…”

Section: Cracksmentioning

confidence: 99%

A Brief Review on The Common Defects in Wire Arc Additive Manufacturing

Albannai¹

2022

ijcsrr

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Wire arc additive manufacturing (WAAM) process, which depends on conventional welding arc processes, is a promising option for industries when compared to typical manufacturing processes for assembling large and complicated products. WAAM process attracting manufacturing industries due to its potential to make large and complicated components with real sharp production run time with almost single step process. The process represents greater material savings, higher material buildup rate and speed, cost savings, lower cycle time, less impact on the environment, and capability of producing large size parts when evaluated with other fabrication methods. This paper focuses on WAAM process and reviews some of the common possible process defects found in variety of studies made previously to summaries a guideline for the causes of such defects and provides some prevention methods found by those studies. Of these common possible defects found in researchers works and reviewed in this work are pores, lack of fusion, cracks, and residual stress.

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“…Recently, nanoparticles have demonstrated a significant potential in eliminating solidification crack in fusion welding and AM [21][22][23][24][25][26][27][28][29][30]. For instance, Sokoluk et al [22] investigated the weldability of Al7075 during TIG welding using TiC-nanoparticles enhanced Al7075 filler metal.…”

Section: Introductionmentioning

confidence: 99%

An adapted approach for solidification crack elimination in Al7075 TIG welding

Abdollahi,

Nganbe,

Kabir

2024

Mater. Res. Express

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Solidification cracking is a long-standing issue in fusion welding of high-strength aluminum alloys like Al7075, imposing limitations on their aerospace and automotive applications. The current study introduces a novel adapted approach in solidification crack elimination by incorporating TiC nanoparticles into the fusion zone using a filler paste as an easier to fabricate alternative to filler metals investigated so far. To assess the weldability of the proposed method, 3-mm thick Al7075 sheets were TIG welded (i) autogenously without any TiC nanoparticles (autogenous), (ii) heterogeneously using 1 vol.% TiC-nanoparticle enhanced Al7075 filler metal (heterogeneous filler metal), and (iii) heterogeneously using an in-house fabricated Al7075 paste containing 1 vol.% TiC nanoparticles (heterogeneous filler paste). Macroscopic analysis of weld specimens proved that both heterogeneous welding approaches effectively eliminated solidification cracks. This was confirmed by Houldcroft solidification susceptibility index deduction tests that demonstrated a strong reduction in solidification crack susceptibly in all heterogeneous joints as compared to the autogenous joint. Microstructural analysis confirmed the transformation from columnar to equiaxed grain morphology in the fusion zone as crucial factor in crack elimination. Overall, the proposed filler paste method represents a highly cost-efficient approach for eliminating solidification cracks in TIG joining of difficult to weld aluminium alloys.

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Gas-Tungsten Arc Welding of Dissimilar Aluminum Alloys With Nano-Treated Filler

Cited by 16 publications

References 33 publications

Natural aging of heterogeneous arc-welded AA6061-AA7075 joints with nanocomposite filler

Natural aging of heterogeneous arc-welded AA6061-AA7075 joints with nanocomposite filler

A Brief Review on The Common Defects in Wire Arc Additive Manufacturing

An adapted approach for solidification crack elimination in Al7075 TIG welding

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