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Aluminium and its alloys are used in fabrications because of their low weight, good corrosion resistance and weldability.
Although normally low strength, some of the more complex alloys can have mechanical properties equivalent to steels. The
various types of aluminium alloy are identified and guidance is given on fabricating components without impairing corrosion
and mechanical properties of the material or introducing imperfections into the weld.
Material types
As pure aluminium is relatively soft, small amounts of alloying elements are added to produce a range of mechanical
properties. The alloys are grouped according to the principal alloying elements, specific commercial alloys have a four-digit
designation according to the international specifications for wrought alloys or the ISO alpha - numeric system. The alloys can
be further classified according to the means by which the alloying elements develop mechanical properties, non-heat-
treatable or heat-treatable alloys.
Non-heat-treatable alloys
Material strength depends on the effect of work hardening and solid solution hardening of alloy elements such as
magnesium, and manganese; the alloying elements are mainly found in the 1xxx, 3xxx and 5xxx series of alloys. When
welded, these alloys may lose the effects of work hardening which results in softening of the HAZ adjacent to the weld.
Heat-treatable alloys
Material hardness and strength depend on alloy composition and heat treatment (solution heat treatment and quenching
followed by either natural or artificial ageing produces a fine dispersion of the alloying constituents). Principal alloying
elements are defined in the 2xxx, 6xxx and 7xxx series. Fusion welding redistributes the hardening constituents in the HAZ
which locally reduces material strength.
Processes
Most of the wrought grades in the 1xxx, 3xxx, 5xxx, 6xxx and medium strength 7xxx (e.g. 7020) series can be fusion welded
using TIG, MIG and oxyfuel processes. The 5xxx series alloys, in particular, have excellent weldability. High strength alloys
(e.g. 7010 and 7050) and most of the 2xxx series are not recommended for fusion welding because they are prone to
liquation and solidification cracking. The technique of Friction Stir Welding is particularly suited to aluminium alloys. It is
capable of producing sound welds in many alloys, including those heat treatable alloys which are prone to hot cracking
during fusion welding.
Filler alloys
Filler metal composition is determined by:
weldability of the parent metal
minimum mechanical properties of the weld metal
corrosion resistance
anodic coating requirements
Nominally matching filler metals are often employed for non-heat-treatable alloys. However, for alloy-lean materials and
heat-treatable alloys, non-matching fillers are used to prevent solidification cracking.
The choice of filler metal composition for the various weldable alloys is specified in BS EN 1011 Pt 4:2000 for TIG and MIG
welding; recommended filler metal compositions for the more commonly used alloys are given in the Table.
Alloy Chemical Classificatio Filler Application
Designation Designation n
EN AW-1080A EN AW-Al 99.8(A) NHT R-1080A Chemical plant
EN AW-3103 EN AW-Al Mn1 NHT R-3103 Buildings, heat exchangers
EN AW-4043A EN AW-Al Si5(A) - - Filler wire/rod
EN AW-5083 EN AW-Al Mg4.5Mn0.7 NHT R-5556A Ships, rail wagons, bridges
EN AW-5251 EN AW-Al Mg2Mn0.3 NHT R-5356 Road vehicles, marine
EN AW-5356 EN AW-Al Mg5Cr(A) - - Filler wire/rod
EN AW-5556A EN AW-Al Mg5Mn - - Filer wire/rod
EN AW-6061 EN AW-Al Mg1SiCu HT R-4043A, R- Structural, pipes
5356
EN AW-7020 EN AW-Al Zn4.5Mg1 HT R-5556A Structural, transport
HT = Heat treatable, NHT = Non Heat treatable
Imperfections in welds
Aluminium and its alloys can be readily welded providing appropriate precautions are taken. The most likely imperfections in
fusion welds are:
porosity
cracking
poor weld bead profile
Porosity
Porosity is often regarded as an inherent feature of MIG welds; typical appearance of finely distributed porosity in a TIG weld
is shown in the photograph. The main cause of porosity is absorption of hydrogen in the weld pool which forms discrete pores
in the solidifying weld metal. The most common sources of hydrogen are hydrocarbons and moisture from contaminants on
the parent material and filler wire surfaces, and water vapour from the shielding gas atmosphere. Even trace levels of
hydrogen may exceed the threshold concentration required to nucleate bubbles in the weld pool, aluminium being one of the
metals most susceptible to porosity. To minimise the risk, rigorous cleaning of material surface and filler wire should be
carried out. Three cleaning techniques are suitable; mechanical cleaning, solvent degreasing and chemical etch cleaning.
In gas shielded welding, air entrainment should be avoided by making sure there is an efficient gas shield and the arc is
protected from draughts. Precautions should also be taken to avoid water vapour pickup from gas lines and welding
equipment; it is recommended that the welding system is purged for about an hour before use.
Mechanical cleaning
Wire brushing (stainless steel bristles), scraping or filing can be used to remove surface oxide and contaminants. Degreasing should be carried out before
mechanical cleaning.
Solvents
Dipping, spraying or wiping with organic solvents can be used to remove grease, oil, dirt and loose particles.
Chemical etching
A solution of 5% sodium hydroxide can be used for batch cleaning but this should be followed by rinsing in HNO 3 and water to remove reaction products on
the surface.
Solidification cracks
Cracking occurs in aluminium alloys because of high stresses generated across the weld due to the high thermal expansion
(twice that of steel) and the substantial contraction on solidification - typically 5 % more than in equivalent steel welds.
Solidification cracks form in the centre of the weld, usually extending along the centreline during solidification. Solidification
cracks also occur in the weld crater at the end of the welding operation. The main causes of solidification cracks are as
follows:
incorrect filler wire/parent metal combination
incorrect weld geometry
welding under high restraint conditions
The cracking risk can be reduced by using a non-matching, crack-resistant filler (usually from the 4xxx and 5xxx series
alloys). The disadvantage is that the resulting weld metal may have a lower strength than the parent metal and not respond
to a subsequent heat treatment. The weld bead must be thick enough to withstand contraction stresses. Also, the degree of
restraint on the weld can be minimised by using correct edge preparation, accurate joint set up and correct weld sequence.
Liquation cracking
Liquation cracking occurs in the HAZ, when low melting point films are formed at the grain boundaries. These cannot
withstand the contraction stresses generated when the weld metal solidifies and cools. Heat treatable alloys, particularly
6xxx and 7xxx series alloys, are more susceptible to this type of cracking. The risk can be reduced by using a filler metal with
a lower melting temperature than the parent metal, for example the 6xxx series alloys are welded with a 4xxx filler metal.
However, 4xxx filler metal should not be used to weld high magnesium alloys (such as 5083) as excessive magnesium-
silicide may form at the fusion boundary decreasing ductility and increasing crack sensitivity.
Poor weld bead profile
Incorrect welding parameter settings or poor welder technique can introduce weld profile imperfections such as lack of
fusion, lack of penetration and undercut. The high thermal conductivity of aluminium and the rapidly solidifying weld pool
make these alloys particularly susceptible to profile imperfections.
Understanding The Alloys Of Aluminum
With the growth of aluminum within the welding fabrication industry, and its acceptance as an excellent alternative to steel
for many applications, there are increasing requirements for those involved with developing aluminum projects to become
more familiar with this group of materials. To fully understand aluminum,it is advisable to start by becoming acquainted with
the aluminum identification / designation system, the many aluminum alloys available and their characteristics.
The Aluminum Alloy Temper and Designation System - In North America, The Aluminum Association Inc. is responsible for the
allocation and registration of aluminum alloys. Currently there are over 400 wrought aluminum and wrought aluminum alloys
and over 200 aluminum alloys in the form of castings and ingots registered with the Aluminum Association. The alloy
chemical composition limits for all of these registered alloys are contained in the Aluminum Associations Teal Book entitled
International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys
and in their Pink Book entitled Designations and Chemical Composition Limits for Aluminum Alloys in the Form of Castings
and Ingot. These publications can be extremely useful to the welding engineer when developing welding procedures, and
when the consideration of chemistry and its association with crack sensitivity is of importance.
Aluminum alloys can be categorized into a number of groups based on the particular materials characteristics such as its
ability to respond to thermal and mechanical treatment and the primary alloying element added to the aluminum alloy. When
we consider the numbering / identification system used for aluminum alloys, the above characteristics are identified. The
wrought and cast aluminums have different systems of identification. The wrought system is a 4-digit system and the
castings having a 3-digit and 1-decimal place system.
Wrought Alloy Designation System - We shall first consider the 4-digit wrought aluminum alloy identification system. The first
digit (Xxxx) indicates the principal alloying element, which has been added to the aluminum alloy and is often used to
describe the aluminum alloy series, i.e., 1000 series, 2000 series, 3000 series, up to 8000 series (see table 1).
The second single digit (xXxx), if different from 0, indicates a modification of the specific alloy, and the third and fourth digits
(xxXX) are arbitrary numbers given to identify a specific alloy in the series. Example: In alloy 5183, the number 5 indicates
that it is of the magnesium alloy series, the 1 indicates that it is the 1st modification to the original alloy 5083, and the 83
identifies it in the 5xxx series.
The only exception to this alloy numbering system is with the 1xxx series aluminum alloys (pure aluminums) in which case,
the last 2 digits provide the minimum aluminum percentage above 99%, i.e., Alloy 13(50) (99.50% minimum aluminum).
WROUGHT ALUMINUM ALLOY DESIGNATION SYSTEM
Alloy Principal Alloying
Series Element
1xxx 99.000% Minimum
Aluminum
2xxx Copper
3xxx Manganese
4xxx Silicon
5xxx Magnesium
6xxx Magnesium and Silicon
7xxx Zinc
8xxx Other Elements
Table 1
Cast Alloy Designation - The cast alloy designation system is based on a 3 digit-plus decimal designation xxx.x (i.e.
356.0). The first digit (Xxx.x) indicates the principal alloying element, which has been added to the aluminum alloy (see table
2).
CAST ALUMINUM ALLOY DESIGNATION SYSTEM
Alloy Principal Alloying Element
Series
1xx.x 99.000% minimum Aluminum
2xx.x Copper
3xx.x Silicon Plus Copper and/or
Magnesium
4xx.x Silicon
5xx.x Magnesium
6xx.x Unused Series
7xx.x Zinc
8xx.x Tin
9xx.x Other Elements
Table 2
The second and third digits (xXX.x) are arbitrary numbers given to identify a specific alloy in the series. The number
following the decimal point indicates whether the alloy is a casting (.0) or an ingot (.1 or .2). A capital letter prefix indicates a
modification to a specific alloy.
Example: Alloy - A356.0 the capital A (Axxx.x) indicates a modification of alloy 356.0. The number 3 (A3xx.x) indicates that it
is of the silicon plus copper and/or magnesium series. The 56 in (Ax56.0) identifies the alloy within the 3xx.x series, and the .
0 (Axxx.0) indicates that it is a final shape casting and not an ingot.
The Aluminum Temper Designation System - If we consider the different series of aluminum alloys, we will see that there are
considerable differences in their characteristics and consequent application. The first point to recognize, after understanding
the identification system, is that there are two distinctly different types of aluminum within the series mentioned above.
These are the Heat Treatable Aluminum alloys (those which can gain strength through the addition of heat) and the Non-Heat
Treatable Aluminum alloys. This distinction is particularly important when considering the affects of arc welding on these two
types of materials.
The 1xxx, 3xxx, and 5xxx series wrought aluminum alloys are non-heat treatable and are strain hardenable only. The 2xxx,
6xxx, and 7xxx series wrought aluminum alloys are heat treatable and the 4xxx series consist of both heat treatable and
non-heat treatable alloys. The 2xx.x, 3xx.x, 4xx.x and 7xx.x series cast alloys are heat treatable. Strain hardening is not
generally applied to castings.
The heat treatable alloys acquire their optimum mechanical properties through a process of thermal treatment, the most
common thermal treatments being Solution Heat Treatment and Artificial Aging. Solution Heat Treatment is the process of
heating the alloy to an elevated temperature (around 990 Deg. F) in order to put the alloying elements or compounds into
solution. This is followed by quenching, usually in water, to produce a supersaturated solution at room temperature. Solution
heat treatment is usually followed by aging. Aging is the precipitation of a portion of the elements or compounds from a
supersaturated solution in order to yield desirable properties.
The non-heat treatable alloys acquire their optimum mechanical properties through Strain Hardening. Strain hardening is the
method of increasing strength through the application of cold working.T6, 6063-T4, 5052-H32, 5083-H112.
THE BASIC TEMPER DESIGNATIONS
Letter Meaning
6XXX Series Alloys (heat treatable with ultimate tensile strength of 18 to 58 ksi) These are the aluminum /
magnesium - silicon alloys (magnesium and silicon additions of around 1.0%) and are found widely throughout the welding
fabrication industry, used predominantly in the form of extrusions, and incorporated in many structural components. The
addition of magnesium and silicon to aluminum produces a compound of magnesium-silicide, which provides this material its
ability to become solution heat treated for improved strength. These alloys are naturally solidification crack sensitive, and for
this reason, they should not be arc welded autogenously (without filler material). The addition of adequate amounts of filler
material during the arc welding process is essential in order to provide dilution of the base material, thereby preventing the
hot cracking problem. They are welded with both 4xxx and 5xxx filler materials, dependent on the application and service
requirements.
7XXX Series Alloys (heat treatable with ultimate tensile strength of 32 to 88 ksi) These are the aluminum / zinc alloys (zinc
additions ranging from 0.8 to 12.0%) and comprise some of the highest strength aluminum alloys. These alloys are often
used in high performance applications such as aircraft, aerospace, and competitive sporting equipment. Like the 2xxx series
of alloys, this series incorporates alloys which are considered unsuitable candidates for arc welding, and others, which are
often arc welded successfully. The commonly welded alloys in this series, such as 7005, are predominantly welded with the
5xxx series filler alloys.
Summary - Todays aluminum alloys, together with their various tempers, comprise a wide and versatile range of
manufacturing materials. For optimum product design and successful welding procedure development, it is important to
understand the differences between the many alloys available and their various performance and weldability characteristics.
When developing arc welding procedures for these different alloys, consideration must be given to the specific alloy being
welded. It is often said that arc welding of aluminum is not difficult, its just different. I believe that an important part of
understanding these differences is to become familiar with the various alloys, their characteristics, and their identification
system.