ORIGINAL ARTICLE

Thermo-mechanical treatments of Sc- and Mg-modified

AlCu alloy welds
S. R. Koteswara Rao & B. Kamsala Devi &
K. Sreenivasa Rao & K. Prasad Rao
Received: 17 February 2008 / Accepted: 14 January 2009 / Published online: 11 February 2009
# Springer-Verlag London Limited 2009
Abstract High-strength heat-treatable aluminum alloy
AA2219 finds application in aerospace industries. Though it
has good weldability, with alternating currenttungsten inert
gas welding, the joint efficiency obtained is only 40%,
particularly in thicker plates. In the present study, an attempt
has been made to improve the weld metal properties by
modifying the chemistry of fusion zone and post-weld
thermo-mechanical treatments. Fillers were made through
casting route by melting conventional 2319 filler with Sc and
Mg. Two levels of Sc (0.3% and 0.6%) and four levels of Mg
(0.3% to 0.6%) were varied. Compressive deformation was
done on the fusion zone of the weld to get three levels of
percentage of reduction (4%, 8%, and 12%). As welded
specimens and welds after compressive deformation, those
were subjected to post-weld aging treatments at 190C for
different periods up to 100 h. Compressive deformation on the
welds made with modified filler of 2319 with Sc and Mg
resulted in significant improvement in the weld metal strength.
Keywords AlCu alloy weld
.
Scandium
.
Compressive deformation
.
Fusion zone
.
Aging
.
Thermo-mechanical treatment
1 Introduction
High-strength heat-treatable aluminum alloys belonging to
2xxx are attractive materials for aerospace applications. These
applications involve structural components such as rocket
shells, cryogenic tanks, engine casings, and some other small
components. AA 2219 with 6% copper is considered to be the
most weldable among the commercial high-strength aluminum
alloys because of its resistance to cracking. AA 2219 has high
levels of alloying elements and there is excess liquid available
during solidification, which flows into the cracks and heals the
cracks. Though AA 2219 has good weldability, with gas
shielded arc welding, the weld strength is less than half that of
base metal strength [1]. This is true both in autogenous welds
as well as those welded with the matching filler 2319, which
has slightly higher contents of Ti and Zr. The reduction in
strength is due to the dissolution of strengthening precipitates
during melting and high cooling rates involved in welding.
The addition of scandium (Sc) has recently generated
considerable interest to the aluminum welding community.
Small additions of Sc have been found to improve the weld
strength considerably [2]. Mg addition along with Sc has been
proved to improve the beneficial effects of scandium [3].
Therefore, modification of conventional 2319 filler with
Sc and Mg will be advantageous. Furthermore, thermo-
mechanical treatments such as planishing in welds are
expected to exert a beneficial effect with and without post-
planished aging. Compressive deformation of welds,
particularly the fusion zone, has found application in the
form of roll planishing of welds to improve the mechanical
properties of welded joints. It was reported by L.I.
Gladstein [4] that crushing or cold working of the fusion
zone by planishing improves the strength of the welded
joint by reducing porosity, changing the residual stress
condition, and weakening the effect of minor inclusions in
Int J Adv Manuf Technol (2009) 45:1624
DOI 10.1007/s00170-009-1936-8
S. R. Koteswara Rao
Principal, Tagore Engineering College,
Chennai 600048, India
B. Kamsala Devi
:
K. Prasad Rao
Metallurgical and Materials Engineering Department,
IIT-Madras, Chennai 600036, India
K. Sreenivasa Rao (*)
Metallurgical Engineering Department,
A.U. College of Engineering (A),
Visakapatnam 530003, India
e-mail: arunaraok@yahoo.com
steel weld metals. It was reported by Kurkino [5] that
compressive deformation of the fusion zone, what they called
as roller treatment, offsets a high percentage of longitudinal
and lateral shrinkage by crushing down the seam, relieves the
stress patterns, and smoothens out the weld edges resulting in
better tensile properties. Application of elastic stress during
the aging process of age-hardenable aluminum alloys was
also reported to improve the mechanical properties by altering
the distribution of strengthening precipitates. This effect was
also observed in AlCu alloys [6].
Keeping the above factors in view, in the present work,
compressive deformation with and without aging treatments
has been carried out on AA 2219 welds.
2 Experimental
The alloys cast to get the modified 2319 composition were
obtained from appropriate mixtures of commercial-purity
aluminum (99.7%), Al2% Sc master alloy, high-purity Cu
granules (99.9%), Al5% Ti master alloy, and Al3.5% Zr
master alloy. All of the alloys used for this study were
melted in-house in an electrical resistance furnace. The
casting consists of two parts: cylindrical rods of 6-mm
diameter and 120-mm length and a plate-like (7070 mm)
bottom portion. The castings were machined to remove any
surface contamination, degreased, and cleaned. The rods
were used for welding. The plate portion was used for
doing thermo-mechanical treatment on castings. The cast
plates were subjected to homogenization treatment at 535C
for 1 h in an air-cooled furnace before further treatments.
The compositions of the cast alloys are presented in Table 1.
The values correspond to the average of three spectral
analyses and the Sc contents were calculated based on the
amount of AlSc master alloy added to the melt.
A Miller-Synchrowave 350 power source was used to
make gas tungsten arc welds on 2219 plates. All the welds
for this study were made using AC-GTA welding. The
parameters used for welding are given in Table 2. Welding
was done by placing the cast filler rods in a rectangular
groove machined in 2219 T87 base plate and running a gas
tungsten arc to make welds of at least 6 mm deep in a plate of
7.5-mm thickness. The fusion zone compositions are given in
Table 3. The specimens were deformed to three different
percentages of deformation (4%, 8%, and 12%) by passing
them in between the steel rollers. In case of weld, rolling was
done in transverse direction such that only the crown gets
flattened. Strength increment after deformation was measured
by hardness testing. The aging temperature range for AA
2219 is 165190C and aging was done at 190C up to 100 h
for both welds and castings. Vickers hardness measurements
were done at regular intervals during aging. Tensile tests were
conducted in a microprocessor-controlled servo hydraulic
universal testing machine (Schenk) with extensometer attach-
ment on subsize samples made according to ASTM E-8 M
standard. Microstructural examinations were carried out using
an optical microscope (Leica, DMLM). Transmission electron
microscopic (TEM) studies were done on welds and casting
to find the distribution and morphology of precipitates before
and after thermo-mechanical treatment.
3 Results and discussion
The microstructures of base metal (2219-T87) and 2319
weld fusion zone microstructure are shown in Fig. 1.
Fusion zone showed the long columnar grains. It has been
shown that it is possible to replace the columnar grains with
equiaxed grains and reduce overall grain size. This is
achieved by creating and maintaining free nuclei in the
molten weld pool by addition of nucleants to the pool. This
is achieved by the addition of Sc into the weld metal.
Scandium is one of the most effective modifiers of a cast
grain structure in aluminum alloys. This is evident from the
fusion zone microstructures of Sc-added welds. These
Table 1 As welded fusion zone tensile strength values
Composition As-welded
Yield (MPa) UTS (MPa) Ductility (%)
2219T87 365 475 19.8
2319 125 229 4.7
0.3 Sc 142 249 9.2
0.3 Sc + 0.4 Mg 158 271 10.4
0.6 Sc + 0.45 Mg 168 275 8.6
Table 2 Tensile test values of weld fusion zones after compressive
deformation
Composition 8% deformed
Yield (MPa) UTS (MPa) Ductility (%)
0.3 Sc 192 280 9.7
0.3 Sc + 0.4 Mg 264 306 7.2
0.6 Sc + 0.45 Mg 266 306 7.4
Table 3 Tensile strength values of weld fusion zones after compres-
sive deformation + aging
Composition 8% deformed + 9 h aging at 190C
Yield (MPa) UTS (MPa) Ductility (%)
0.3 Sc 232 298 10.5
0.3 Sc + 0.4 Mg 272 310 11.9
0.6 Sc + 0.45 Mg 245 299.6 11.1
Int J Adv Manuf Technol (2009) 45:1624 17
modified composition welds showed equiaxed grains
instead of columnar as in 2319 fusion zone (Fig. 2). When
Sc is added to Al, it forms dispersoids called Al
3
Sc. It has
L1
2
structure with scandium atoms at the corners and
aluminum atoms at the face centers. These primary
intermetallic particles act as potent heterogeneous nucle-
ation sites within the melt due to their high coherency and
low interfacial energy with the Al matrix. Scandium
aluminide and aluminum have the same lattice type and the
discrepancy between lattice parameters is about 1.5%.
Therefore, the Al grains can easily nucleate on the surface
of the Al
3
Sc precipitates. That is the reason why, even with
the 0.3% addition of Sc, the fusion zone microstructure
changed from long columnar grains to equiaxed flower-like
grains. However, addition of 0.6% Sc showed still further
grain refinement. The Al-rich end of AlSc phase diagram
is shown in Fig. 3 [7]. The presence of 0.6% of Sc comes in
the hyper-eutectic (above 0.55 wt.%) composition. So, for
this composition, the number of primary Al
3
Sc particles
available per unit volume will be higher when compared to
0.3% of Sc. That is the reason why the fusion zone with
0.6% Sc showed more grain refinement.
When compared to the 2319 + Sc welds, 2319 + Sc +
Mg weld fusion zones showed finer grains (Fig. 4). The 0.3
Sc + 0.4 Mg fusion zone showed more refinement
compared to that of 0.3 Sc fusion zone (Fig. 2). However,
when the Sc percentage was hyper-eutectic, with 0.3% Mg
the grain refinement was still significant. This noticeable
grain refinement occurred because of two reasons. Firstly,
Mg addition increases the lattice parameter of Al matrix;
this further decreases the lattice parameter discrepancy
between -Al and Al
3
Sc. Secondly, it has been reported
that Mg clusters act as a nucleation site for Al
3
Sc
precipitates [8]. Therefore, the number of heterogeneous
nucleation sites per unit volume increases. In addition, Zr
present in the fusion zone forms Al
3
(Sc, Zr) phase whose
lattice difference with the Al-matrix is still lower than
Al
3
Sc. Therefore, Zr increased the effectiveness of modi-
fying action. So, Zr addition reduced the amount of Sc
needed for effective grain refinement. The as-welded fusion
zone hardness values are given in Fig. 5. The base metal
hardness was 148 Vickers hardness number (VHN). When
compared to base metal hardness, the fusion zone hardness
value of 2319 weld was 78 VHN, which is only about 50%
Fig. 2 Fusion zone micro structure of 2319 + 0.6 Sc welds showing
equiaxed grains Fig. 3 Al-rich end of AlSc phase diagram
Fig. 1 Fusion zone microstruc-
tures 2219 T87 (a) base metal
and (b) 2319 weld showing
columnar grains
18 Int J Adv Manuf Technol (2009) 45:1624
of the base metal strength. This drastic reduction is because of
the dissolution of strengthening precipitates during welding.
The TEM pictures for the base metal and 2319 weld are given
in Fig. 6. The base metal showed dense distribution of Al
2
Cu
precipitates, whereas for 2319 fusion zone very few
precipitates were found. This dissolution of precipitates is
because of the large heat input and high cooling rate involved
in arc welding. With addition of 0.3% and 0.6% of Sc, there
was also no increment in fusion zone hardness. Though there
was significant reduction in the grain size in the Sc-added
welds, it was not reflected in hardness values. This could be
because of the nonavailability of a sufficient amount of Al
3
Sc
strengthening precipitates in the as-welded condition. The
TEM picture for 2319 + 0.6 Sc weld fusion zone is given in
Fig. 7. The TEM picture showed some spherical dispersoids.
These rounded precipitates were confirmed earlier as Al
3
Sc
primary particles [9]. The driving force available for Al
3
Sc
dispersoids to precipitate in the as-welded condition was very
low. There is no report about the precipitation of Al
3
Sc
dispersoids at room temperature. Therefore, the rounded
particles in the TEM picture are the primary particles from the
filler. These primary particles acted as heterogeneous nucle-
ation sites and caused good grain refinement, but they were
not significant in improving the fusion zone strength.
Fig. 4 Fusion zone microstructures of welds a 2319 + 0.3 Sc + 0.4 Mg, b 2319 + 0.6 Sc + 0.3 Mg, c 2319 + 0.6 Sc + 0.45 Mg, d 2319 + 0.6 Sc +
0.63 Mg
Fig. 5 As-welded fusion zone hardness values
Int J Adv Manuf Technol (2009) 45:1624 19
For the 2319 + Sc + Mg welds, there was some
improvement in the fusion zone hardness values when
compared to welds with 2319 + Sc welds. For the 2319 + 0.3
Sc + 0.4 Mg weld, there was nearly a 20-VHNincrement in the
fusion zone hardness. There are two reasons for this increment.
When Mg was added to aluminum, it gave solid solution
strengthening because of atomic misfit. Another reason could
be formation of omega () precipitates by natural aging. The
TEM picture for 2319 + 0.3 Sc + 0.4 Mg weld fusion zone is
given in Fig. 8. In order to determine the relationship between
grain morphology and mechanical properties of the weld
metal, transverse tensile tests (i.e., the test specimens being
perpendicular to the weld direction) were carried out. Tensile
tests were done only for three compositions since there was
no significant variation in the fusion zone hardness values.
The values for 2219 T87 base metal, 2319, and other
modified composition welds are given in Table 1. The yield
strength of 2319 weld was nearly one third when compared
to base metal. In addition, there was a drastic decrease in the
ductility. This poor ductility is because of the columnar
dendritic structure of the fusion zone. For all the welds,
specimens fractured in the fusion zone. With Sc and Sc + Mg
addition, there was a significant increase of about 20 to
40 MPa in fusion zone yield strength. The improvement in
percentage of elongation was attributed to the fine-grain
structure of the fusion zone.
The response of the Sc-added weld fusion zone to
compressive deformation is given in Fig. 9. Both 0.3% and
0.6% Sc welds showed a linear increase in fusion zone
hardness with the increase in the percentage of deformation.
For the 0.3% Sc weld, the increase was gradual and peak
hardness was obtained for 12% of deformation. In the 0.6%
Sc weld, there was a 25-VHN increment within 4% of
deformation and then no significant increment with increase
in percentage of deformation. The effect of rolling on
fusion zone hardness values for 2319 + Sc + Mg welds is
given Fig. 10. Compared to 2319 + Sc welds, 2319 + Sc +
Fig. 7 TEM of 2319 + 0.6 Sc weld fusion zone
Fig. 6 TEM of a base metal
and b 2319 weld
Fig. 8 TEM of 2319 + 0.3 Sc + 0.4 Mg weld fusion zone
20 Int J Adv Manuf Technol (2009) 45:1624
Mg welds showed an increased response to compressive
deformation, i.e., the increase in the fusion zone hardness
values with increase in percentage of deformation is
significant. All the Sc + Mg welds showed a drastic
increment in fusion zone hardness for even 4% of
deformation. In the case of 0.3 Sc + 0.4 Mg-added weld
for 8% of deformation, there was an increment of about 45
VHN in fusion zone hardness. This increment caused the
fusion zone to gain strength of nearly 85% as that of base
metal 2219 T87. Compared to 0.3 Sc + 0.4 Mg weld, 0.6 Sc +
0.3 Mg weld showed a decreased response to compressive
deformation. By increasing the Mg content from 0.3 to 0.45,
the increase in fusion zone hardness did not also come up to
the level of 0.3 Sc + 0.4 Mg, but for 0.63% addition of Mg
there was a significant increase in fusion zone hardness and
these hardness values were similar to that of 0.3 Sc + 0.4 Mg
welds. Therefore, the point that should be noted here is that
the increase in Sc percentage from 0.3 to 0.6 did not result in
any significant response to compressive deformation.
Actually, with increase in Sc percentage, the response of
fusion zone hardness came down. The reason for this
decreased response could be due to the formation of W
phase with the increase in the percentage of Sc. This
phase forms in the AlCuSc alloys (Fig. 11). The
precipitation and strengthening ability of the W phase is
more uncertain. However, as its formation would decrease
the quantity of and Al
3
Sc precipitates, it is probable that
its presence is undesirable. Usually, this W phase is
associated with high cooling rates [10]. Since arc welding
process involves a higher rate of cooling, the possibility of
W phase formation is higher.
Therefore, for all the welds, the increase in fusion zone
hardness is attributed by two factors, strain hardening or
work hardening due to compressive deformation and
formation of strengthening precipitates at room temperature
itself by natural aging.
Fig. 9 Effect of compressive deformation on fusion zone hardness
values of 2319 + Sc welds
Fig. 10 Effect of compressive deformation on fusion zone hardness
values of 2319 + Sc + Mg welds
Fig. 11 Isothermal section of Al corner of AlCuSc phase diagram
at 500C
Fig. 12 TEM of deformed 2319 + 0.6 Sc weld fusion zone
Int J Adv Manuf Technol (2009) 45:1624 21
Though strain hardening contributes more to increase in
fusion zone hardness, there could be some increase because
of precipitation at room temperature. To study the effect of
natural aging, transmission electron microscopic studies
were done on some of the deformed samples. The TEM
picture of 2319 + 0.6 Sc weld fusion zone (Fig. 12) showed
only the presence of rod-shaped precipitates. EDS (Fig. 13)
analysis confirms that these are (Al
2
Cu) precipitates.
There were no Al
3
Sc dispersoids. This is because the
driving force available at room temperature is not sufficient
for the Al
3
Sc dispersoids to form. In addition to Al
2
Cu, the
TEM picture showed some dark spots. This could be
because of the residual traces of acid, which was used for
the electro-chemical thinning process. Due to improper
cleaning, these traces were left on the specimen. Transmis-
sion electron micrographs were also taken for 2319 + Sc +
Mg welds (Fig. 14). Here, in addition to Al
2
Cu, there was
another kind of hexagonal-shaped precipitates found. The
compositions of these hexagonal-shaped precipitates were
found to be similar to that of Al
2
Cu with some amount of
Mg. According to the literature, precipitates are the
modified form of with segregation of Mg in the /
interface. Therefore, in addition to , precipitates also
play a role for the increase in strength. The tensile strength
values for three compositions at 8% deformed condition are
given in Table 2. The hardness trend was reflected in tensile
values also. When compared to 0.3% Sc weld, the 0.3%
Sc + 0.4% Mg weld showed an increase of about 70 MPa.
This increment mainly came due to effective strain
hardening in the presence of Mg and the presence of an
additional strengthening precipitate, . Though there was a
good increment in yield strength, the increase in ultimate
tensile strength (UTS) was not significant. Even with an
Fig. 13 TEM EDS of Al
2
Cu
precipitate
Fig. 14 TEM of deformed 2319 + 0.6 Sc + 0.63 Mg weld fusion
zones
Fig. 15 Effect of direct aging at 190C on fusion zone hardness
values of 2319 + Sc welds
22 Int J Adv Manuf Technol (2009) 45:1624
increase in Sc or Mg percentage, it also did not increase
much. When compared to the as-welded condition, the
increase in yield strength was significant for all composi-
tions and especially for Mg-added welds. The increment
from 158 to 264 MPa for the 0.3 Sc + 0.4 Mg weld is a
noticeable increment. The difference in ultimate tensile
strength was not much for the as-welded and deformed
samples. The decrease in percentage of elongation due to
strain hardening was not much when compared to the as-
welded condition. The reason for this good ductility comes
from the fine grain structure.
To study the response of welds for artificial aging, the
welds were subjected to an aging treatment at elevated
temperature (190C) up to 100 h and hardness values were
taken at regular intervals. The response of the 0.3% and
0.6% Sc welds to the aging treatment is given in Fig. 15.
Both welds showed a gradual and very less increase in
fusion zone hardness with increase in aging time, but the
increase in fusion zone hardness with artificial aging was
only about 10 VHN. The response of Sc + Mg welds for
artificial aging treatment is given in Fig. 16. For all the
welds, there was no change in fusion zone hardness values
even for exposures up to 100 h at 190C. An increase in Sc
or Mg content also did not change the response to artificial
aging. Usually, the Al
3
Sc precipitates are sluggish and the
driving force needed for them to nucleate is also high.
Though there was a nucleation of some and
precipitates, their number was not significant and so were
Fig. 16 Effect of direct aging at 190C on fusion zone hardness of
2319 + Sc + Mg welds
Fig. 17 Effect of deformation + aging (190C) on fusion zone
hardness values of 2319 + 0.3 Sc welds
Fig. 18 TEM of 2319 + 0.6 Sc after deformation + aging
Fig. 19 Effect of deformation + aging (190C) on fusion zone
hardness values of 2319 + 0.3 Sc + 0.4 Mg weld
Fig. 20 TEM of 2319 + 0.6 Sc + 0.4 Mg weld fusion zones after
deformation + aging
Int J Adv Manuf Technol (2009) 45:1624 23
the fusion zone hardness values. So, the effect of direct
aging for the composition-modified welds is not significant
when compared to compressive deformation.
The artificial aging treatment was done for all the welds
to get the maximum advantage of precipitation hardening.
The aging treatment at 190C was done for all the three
percentages of deformations in each composition. Date on
the response of 0.3% and 0.6% Sc welds to the aging
treatment are given in Fig. 17. In case of 0.3% Sc weld,
with the increase in aging time, there was a gradual increase
in the fusion zone hardness and a peak hardness of about
100 VHN was obtained. Though there was a gradual
increment in hardness, the peak hardness value was
maintained even after aging up to 100 h. For the 0.6% Sc
weld, there was a decrease in fusion zone hardness during
the initial stages of aging. With the increase in the aging
time, hardness was of a gradual increment and a maximum
value of about 115 VHN was obtained. After aging for
100 h, a fusion zone hardness value of about 90 VHN was
maintained. The TEM picture of 0.6% Sc weld at the peak
aged condition is given in Fig. 18. The TEM clearly
showed the presence of Al
3
(Sc, Zr). From the bulls eye
structure, it is clear that during the nucleation of this
precipitate, initially, Al
3
Zr homogeneously nucleated from
the matrix and on the dislocations created by compressive
deformation. Then, Al
3
Sc dispersoids formed on the surface
of this Al
3
Zr precipitates. In addition to this, there could be
a presence of some Al
2
Cu precipitates. They are not seen in
Fig. 18 since focusing was done in such a way to get the
Al
3
Sc precipitates. Details on the response of 2319 + Sc +
Mg welds for the artificial aging treatment are given in
Fig. 19. For all the compositions, there was a decrement in
the fusion zone hardness values during the initial stages of
aging. With the increase in aging time, there was a gradual
increment and saturation at a reasonably high hardness
value. In all of the cases, peak hardness value of about 120
VHN was obtained. After 100 h of aging, a saturated
hardness value of about 105 VHN was maintained for all
the compositions. During aging, there was a competition
between release of stored energy, recovery, and precipita-
tion. At some point, precipitation exceeded the effect of
recovery and peak fusion zone hardness was obtained. The
distribution of precipitates in the fusion zone after aging is
given in Fig. 20. The precipitation in Sc + Mg welds is a
complicated process. Since different kinds of precipitates
play a role for strength increment, their nucleation and
precipitation kinetics will be different. The possible
precipitates for Sc + Mg composition are Al
2
Cu, , Al
3
(Sc, Zr), and possibly some S. Since the Mg content is low,
the possibility of formation of S is less.
The tensile test results for deformed fusion zones
subjected to aging treatment are given in Table 3. The
artificial aging treatment after compressive deformation
resulted in a significant improvement in tensile properties.
This has been attributed to the grain refinement, strength-
ening precipitates, and strain hardening of the fusion zone
caused by the addition of scandium and magnesium to the
conventional filler of AA2319.
4 Conclusions
Modification of conventional 2319 filler with either Sc or
Sc + Mg has proven to be beneficial in refining the fusion
zone microstructures during welding of AA2219 alloy.
With Sc and Mg addition, there was a significant increase in
fusion zone yield strength. Improvement in percentage of
elongation was attributed to fine grain structure of fusion
zone. The effect of direct aging for the composition-modified
welds is not significant when compared to compressive
deformation. The artificial aging treatment after compressive
deformation resulted in a significant improvement in tensile
properties of fusion zone. This has been attributed to the grain
refinement, strengthening precipitates, and strain hardening of
the fusion zone caused by the addition of scandium and
magnesium to the conventional filler of AA2319.
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