Aluminum Welding Techniques
Transcript of Aluminum Welding Techniques
-
8/8/2019 Aluminum Welding Techniques
1/35
Aluminum WeldingTechniques
Tel. ********
Mobile: ********
E-mail: *****@se.com.sa
-
8/8/2019 Aluminum Welding Techniques
2/35
Aluminium and its alloys
Abundant metal (8% of earthscrust).
Light weight.
Moderate to high strength(depending on alloy).
High conductivity.
Corrosion resistant (Al2O3 coating).
Non-magnetic.
Good reflector.
-
8/8/2019 Aluminum Welding Techniques
3/35
The wrought alloy designation system isbased on a 4 digit designation xxxx
1XXX - Pure Al (99.0%+)
2XXX - Al + Copper.
3XXX - Al + Manganese.
4XXX - Al + Silicon.
5XXX - Al + Magnesium.
6XXX - Al + Magnesium and Silicon.7XXX - Al + Zinc.
8XXX - Al + Other Elements.
Wrought Alloy Designation
-
8/8/2019 Aluminum Welding Techniques
4/35
The first digit (Xxxx) indicates theprincipal alloying element.
The second single digit (xXxx), if
different from 0, indicates a modificationof the specific alloy.
The third and fourth digits (xxXX) are
arbitrary numbers given to identify aspecific alloy in the series.
Wrought Alloy Designation
-
8/8/2019 Aluminum Welding Techniques
5/35
CAST ALLOY DESIGNATION
The cast alloy designation system is based on a 3digit-plus decimal designation xxx.x (i.e. 356.0).
1XX.X - Pure Al (99.0%+)
2XX.X - Al + Copper.
3XX.X - Al + Copper Plus Silicon.
4XX.X - Al + Silicon.
5XX.X - Al + Magnesium.
6XX.X - Al + Magnesium Plus Silicon.
7XX.X - Al + Zinc.
8XX.X - Al + Tin.
9XX.X - Al + Other elements.
-
8/8/2019 Aluminum Welding Techniques
6/35
CAST ALLOY DESIGNATION
The first digit (Xxx.x) indicates theprincipal alloying element.
The second and third digits (xXX.x)are arbitrary numbers given toidentify a specific alloy in the series.
The number following the decimalpoint indicates whether the alloy is acasting (.0) or an ingot (.1 or .2).
-
8/8/2019 Aluminum Welding Techniques
7/35
TEMPER DESIGNATION
The 1xxx, 3xxx, and 5xxx series are
strain hardenablestrain hardenable only.
The 2xxx, 6xxx, and 7xxx series are
heat treatableheat treatable.The 4xxx series consist of both heatheat
treatable and nontreatable and non--heat treatableheat treatable alloys.
The 2xx.x, 3xx.x, 4xx.x and 7xx.xseries are heat treatableheat treatable.
-
8/8/2019 Aluminum Welding Techniques
8/35
TEMPER DESIGNATION
Basic Designations
F - As Fabricated
O - AnnealedH - Strain Hardened
W - Solution Heat Treated
T - Thermally Treated
-
8/8/2019 Aluminum Welding Techniques
9/35
As FabricatedAs Fabricated
Applies to products of aforming process in which no
special control over thermalor strain hardening conditions
is employed.
TEMPER DESIGNATION
-
8/8/2019 Aluminum Welding Techniques
10/35
TEMPER DESIGNATION
AnnealedAnnealed
Applies to product which hasbeen heated to produce the
lowest strength condition toimprove ductility and
dimensional stability
-
8/8/2019 Aluminum Welding Techniques
11/35
TEMPER DESIGNATION
Strain HardenedStrain Hardened
Applies to products that are
strengthened through cold-working. The strain hardening
may be followed by
supplementary thermal
treatment, which produces
some reduction in strength.
-
8/8/2019 Aluminum Welding Techniques
12/35
TEMPER DESIGNATION
Solution Heat TreatedSolution Heat Treated
A process of heating the alloyto an elevated temperature
(990F) in order to put the
alloying elements or
compounds into solution.
-
8/8/2019 Aluminum Welding Techniques
13/35
TEMPER DESIGNATION
Thermally TreatedThermally Treated
Applies to product that hasbeen heat-treated,sometimes with
supplementary strain-hardening, to produce astable temper.
-
8/8/2019 Aluminum Welding Techniques
14/35
TEMPER DESIGNATION
AgingAgingThe precipitation of aportion of the elements orcompounds from asupersaturated solution in
order to yield desirableproperties.
-
8/8/2019 Aluminum Welding Techniques
15/35
SUBDIVISIONS OFHTEMPER
STRAIN HARDENEDThe first digit after the H indicates abasic operation:
H1 -
Strain Hardened Only.H2 - Strain Hardened and PartiallyAnnealed.
H3 - Strain Hardened andStabilized.
H4 - Strain Hardened andLacquered.
-
8/8/2019 Aluminum Welding Techniques
16/35
-
8/8/2019 Aluminum Welding Techniques
17/35
SUBDIVISIONS OFTTEMPER
THERMALLY TREATED
T1 - Air Cool and Natural Aged.
T2 - Air Cool, Cold Worked and Natural
Aged.
T3 - Solution, Cool, ColdWorked and
Natural Aged.
T4 - Solution, Cool and Natural Aged.
T5 - Air Cool and Artificially Aged.
-
8/8/2019 Aluminum Welding Techniques
18/35
SUBDIVISIONS OFTTEMPER
THERMALLY TREATED
T6 - Solution, Water Cool and Artificial Aged.
T7 - Solution, Water Cool and Over Aged.
T8 - Solution, Water Cool, Cold Worked and
Aged.
T9 - Solution, Water Cool, Aged and Cold
Worked.
T10 - Air Cool, ColdWorked and ArtificialAged.
-
8/8/2019 Aluminum Welding Techniques
19/35
ALUMINUM ALLOYS AND
THEIR CHARACTERISTICS11xxx Series Alloys (Nonxxx Series Alloys (Non--heat treatable)heat treatable)
Pure Aluminium
9999..00% minimum aluminum.% minimum aluminum.
Excellent corrosion resistance.Relatively poor mechanical properties.
Excellent electrical and thermalconductivity.
Food, chemical, heat exchangers,electrical wiring, capacitor foil.
Weldable.
-
8/8/2019 Aluminum Welding Techniques
20/35
ALUMINUM ALLOYS AND
THEIR CHARACTERISTICS22xxx Series Alloys (Heat treatable)xxx Series Alloys (Heat treatable)
Aluminum/Copper alloys.
Copper additions ranging from 0.7 to 6.8%
Precipitation hardened.
Excellent strength over a wide range of
temperature.
Aircraft structure and mechanicalcomponents, vehicle body panels.
Weldability poor to fair depending on
alloy.
-
8/8/2019 Aluminum Welding Techniques
21/35
ALUMINUM ALLOYS AND
THEIR CHARACTERISTICS
33xxx Series Alloysxxx Series Alloys (Non(Non--heat treatable)heat treatable)
Aluminum/manganese alloys
Manganese additions ranging fromManganese additions ranging from 00..0505 toto 11..88%%Excellent formability and
weldability.
Very high corrosion resistance.Cans, chemical vessels, industrial
roofing, culvert pipe.
-
8/8/2019 Aluminum Welding Techniques
22/35
ALUMINUM ALLOYS AND
THEIR CHARACTERISTICS
44xxx Series Alloysxxx Series Alloys
(Heat treatable & non(Heat treatable & non--heat treatable)heat treatable)
Aluminum/silicon alloys
Silicon additions ranging from 0.6 to 21.5%Effective Liquidus Suppressant.
Good Wear Property - Cast Alloys.
Inferior corrosion resistance.High temperature parts, pistons.
Weldable.
-
8/8/2019 Aluminum Welding Techniques
23/35
ALUMINUM ALLOYS AND
THEIR CHARACTERISTICS55xxx Series Alloysxxx Series Alloys (Non(Non--heat treatable)heat treatable)
Aluminum/magnesium alloysMagnesium additions ranging from 0.2 to 6.2%
Moderate strength.Good corrosion resistance.
Excellent weldability.
Shipbuilding, transportation,pressure vessels, bridges andbuildings.
-
8/8/2019 Aluminum Welding Techniques
24/35
ALUMINUM ALLOYS AND
THEIR CHARACTERISTICS66xxx Series Alloysxxx Series Alloys (Heat treatable)(Heat treatable)Aluminum/magnesium-silicon alloys
magnesium and silicon additions of around 1.0%
Easily workable.
Excellent strength.
Excellent corrosion resistance.
Limited to excellent weldability.
Pressure vessels, cryogenics,Communication towers, Armour plate,
Marine, auto and aircraft applications.
-
8/8/2019 Aluminum Welding Techniques
25/35
ALUMINUM ALLOYS AND
THEIR CHARACTERISTICS77xxx Series Alloysxxx Series Alloys (Heat treatable)(Heat treatable)Aluminum/zinc alloys
Zinc additions ranging from 0.8 to 12.0%
Highest strength aluminum alloys.
Used where stress corrosion is a problem.
Alloys with Cu can be precipitation hardened.
Unweldable to excellent weldabilitydepending on alloy and process.
Aircraft, aerospace, and competitive sporting
equipment.
-
8/8/2019 Aluminum Welding Techniques
26/35
WELDING ALUMINUM ALLOYS
Aluminum Welding DifficultiesAluminum oxide surface coating.
Al2O3.High thermal conductivity.
Three to five times as fast as steel
High thermal expansion coefficient.2X Steel& welds decrease about 6% in volume
when solidifying.
Low melting temperature.
Absence of color change as temperatureapproaches the melting point.
Prone to contamination by O2, N2, H2.Solidification cracking, particularly of many heat
treatable alloys.
-
8/8/2019 Aluminum Welding Techniques
27/35
WELDING ALUMINUM ALLOYS
Cleaning
Solvent cleaner, mechanical,
etching.Weld pre-cleaning
Mechanical methods plus solvent
wipe
-
8/8/2019 Aluminum Welding Techniques
28/35
FI I
Avoidance of cracking.
Tensile strength of weld.
Weld ductility.Service temperature.
Corrosion resistance.Colour match after anodising.
-
8/8/2019 Aluminum Welding Techniques
29/35
Solidification cracking
Use matching filler for strain-hardenedgrades
Dont mix 4000 series and 5000 seriesalloys (Mg2Si eutectics formed)
Dont mix 5000 series and 2000 seriesalloys
Many heat treatable grades are hotshort
No autogenous welding
Avoid high dilution
Medium copper grades are Unweldable
-
8/8/2019 Aluminum Welding Techniques
30/35
HAZ cracking
Liquation cracking can occur in the
HAZ of age hardenable grades
Keep arc energy lowChoose fillers with a low solidification
temperature
-
8/8/2019 Aluminum Welding Techniques
31/35
Aluminum Welding Procedures
Select Joint Design & Fit up
Bevel angles
Square edge up to 3mm60 to 110 included angle
Determine The Appropriate Inert
Shielding Gas
Argon or Argon/Helium
-
8/8/2019 Aluminum Welding Techniques
32/35
Select The Applicable Filler Metal
60615086505250051100
3003Base Metals
4043
4047
5183
5654
5554
5556
5356
5356
5183
5556
5356
5183
5554
5556
5654
4043
4043
5183
5356
5554
5556
5654
4043
40476061
5356
5183
5556
5356
5183
5556
5356
5183
5556
5356
4043(A)5086
5654
5183
5356
5554
55564043
4043
5183
5356
5556
4047
5183
5356
5556
4043
5052
5183
5356
5556
4043
5183
5356
5556
4043
5005
1100
4043
1100
3003
Sample
-
8/8/2019 Aluminum Welding Techniques
33/35
Set The Parameters
Gas Flow
(cfh)Gas CupAmps
Filler Rod
Size
Tungsten
SizeThickness
203/8"70 - 1001/16" 3/32"1/16" 3/32"1/16"
203/8"90 - 1201/8"3/32" 1/8"3/32"
207/16"125 1751/8" 5/32"1/8" 5/32"1/8"
257/16" 1/2"170 2255/32" 3/16"5/32" 3/16"3/16"
301/2"220 2753/16"3/16" 1/4"1/4"
355/8"330 3803/16" 1/4"1/4"3/8"
-
8/8/2019 Aluminum Welding Techniques
34/35
ALUMINUM WELDING TECHNIQUESAn initial arc is struck on a starting block to
heat the electrode.The arc is held at the starting point until the
metal liquefies and a weld pool is established.
Add filler metal to the front or leading edge of
the pool but to one side of the centerline.Both hands are moved in unison with a slight
backward and forward motion along the joint.
Arc length must be maintained to obtain
sufficient penetration and avoid undercutting.
Gradually lengthen the arc while adding fillermetal to the crater to prevent crater crack whenthe arc is broken.
-
8/8/2019 Aluminum Welding Techniques
35/35