px) The Aluminum Association @® HYDROGEN SOLUBILITY TEMPERATURE °F 1220 4532 Maltin Point + Solubility In Liquid at Melting Point so in Solid H, SOLUBILITY °c, ALLOY CONTENT vs. CRACK SENSITIVITY Pisses RELATIVE CRACK SENSITIVITY ee 4 REE anak COMPOSITION OF WELD -PERCENT ALLOYING ELEMENT SceecseeseseeesecesesecesceaseesesesesseessenaecsWelding Aluminum: Theory and Practice The Aluminum Association www.aluminum.org This book has been edited, revised and expanded by The Aluminum Association and by mernber companies represented on The Aluminum Association's Technical Committee — Welding and Joining, Tony Anderson, AlcoTec Wire Corporation (Committee Chairman) Frank Atmao, Lincoln Electric Company Bill Christy, Alcan International Limited Jo Ann Clarke, Alcan International Limited Pefer Pollak, The Aluminum Association (Secretary) Don Rager, Consultant, Reynolds Metals (Retired) Donald J. Spinella, Alcoa Kyle Williams, Aicoa The committee would like to express its gratitude to the original author of the text, H.L. Saunders. Use of the Information Any data and suggestions contained in this publication were compiled and/or developed by The Aluminum Association, Inc. In view of the variety of conditions and methods of use to ich such data and suggestions may be applied, The Aluminum Association and its member companies assume no responsibilty or lability for the use of information contained herein Neither The Aluminum Association nor any of its member companies gives any warranties, express or implied, with respect to this information, Fourth Edition * 2002ISBN 1-55925-000-3 Copyright © 2002 The Alumirism Association. IncWELDING ALUMINUM Table of Contents Chapter 1: Chapter 2: Chapter 3: Introduction to Aluminum Welding General Welded Aluminum Applications Aluminum's Properties Chemical Properties Physical Properties Mechanical Properties Forms of Aluminum....... Allow and Temper Designation Systems General - Alloying Elements - Wrought Allow Designations Cast Alloy Designations Temper Designations “F" fabricated ... “O” annealed “H’ strain hardened “W" solution heat-treated "T’ thermally treated to produce stable tempers other than F, O, or H ‘Aluminum Alloy Properties Welding Metallurgy General . Major Differences Between Aluminum and Steel Alloying Aluminum Wrought Alloys Nonheat-Treatable Alloys ‘xx Series Alloys 3xxx Series Alloys. do Series Alloys. 5xaxx Series Alloys. Heat-Treatable Alloys 2xxx Series Alloys Gwx Series Alloys Txxx Series Alloys. Bxxx Series Alloys. Cast Alloys Weld Cracking ‘Common Filler Alloys. Filler Alloy Selection Alloys 5356, 5183 and 5556. Alloy 5854 1 44 at 14 12 12 13 at 24 24 at 22 22 2.2 2.2 22 22 23 34 34 34 33 33 33 34 3.4 34 34 34 34 35 35 35 3.6 37 a7 37 38WELDING ALUMINUM Chapter 4: Chapter 5: Alloy 5654 Alloys 4043, 4643, 4047 and 4145, Alloy 2319 Alloys 1100 and 1188 ... : Alloys C955.0, A356.0, 357.0 and A357.0 .. Special Cases... Metallurgical Effects of Welding Weld Bead Weld Heat-AMfected Zones Nonheat-Treatable Alloys Heat-Treatable Alloys Welding Annealed Heat-Treatable Base Alloys Postweld Heat-Treatment . Thermal Stress Relief : Precautions When Welding Some High Performance Aluminum Alloys oo. Metal Preparation for Welding General Storage and Handling of Aluminum Metalworking Methods Are Cutting, Beveling and Gouging Air Carbon Arc Cutting, Beveling and Gouging Plasma Arc Cutting, Beveling and Gouging Laser Cutting Mechanical Cutting, Beveling and Gouging Sawing Grinding Gouging Other Methods Cleaning Techniques. Solvents Deoxidizers Wire Brushing Additional Operations Moisture Removal Preheating Interpass Operations Weld Backing Fixturing Tack Welding ‘Smut Removal Repairing Welds Distortion Control 38 3.8 3.10 3.10 23.10 3.10 3.10 3.11 B11 3.11 3.11 23.15 3.15 3.16 BAT 44 at 44 44 at 42 44 44 44 45 45 46 46 az 47 47 54 54 54 52 52 52 53 53 54Table of Contents Chapter 6: Gas Tungsten Arc Wetding General 64 AC-GTAW : - : - 62 Equipment - 62 Power Sources... : 62 Shielding Gas .. : ~ 63 Welding Torches - : - 63 Tungsten Electrodes - : : 63 Cooling Systems nn... . - 64 Filler Metal ...... . a 65 Manual Welding Technique on : 65 Joint Geometry .... . ey Welding Procedure . 67 Pipe Welding ....... : 6.13 Automatic Welding... : . 6.13 DC-GTAW..... : 6.14 Equipment - 6.14 Power Sources 6.14 Shielding Gas : 6.14 Welding Torches, 6.15 Tungsten Electrodes 6.15 Cooling Systems : 6.415 Filler Metal : 615 Manual Welding Techniques 6.16 Automatic Welding... : 6.18 Chapter 7: Gas iMfetal Arc Welding General a ‘The GMAW Process 7A Equipment [ 72 Power Sources 72 Pulsed GMAW 74 Are Stability 75 Joint Geometry 78 Poo! Dynamics 75 Electrode Feeder and Gun 76 Arc Initiation 7 Guns 7? Contact Tips... 78 Shielding Gas 78 Cooling Systems. 79 Electrode Wire 79 Semiautomatic Welding ve 79 Joint Geometry . 712 Welding Procedure. 7.43 Setting a Procedure e 715 Initiating the Arc = 716 Welding TAT Stopping the Arc TATWELDING ALUMINUM Automatic Welding soonest 7.18 Equipment a 7.18 Power Sources cere 7.19 Electrode Feeder and Gun . a 7.19 Shielding Gas ..... : 720 Robotic Welding ..... 7.20 Orbital Pipe Welding... ei GMA Spot Welding = 721 Chapter 8: Electron Beam Welding General cesses . 8.1 Fundamentals of Creating an Electron Beam at Characteristics of the Process 8.1 Welding Process Variations : ee Chapter 9: Laser Beam Welding General ae 9.1 Fundamentals of Creating a Laser Beam... 94 Characteristics of the Process vs 9.1 CO, Laser 92 Nd:YAG Laser 9.2 Direct Diode 93 Hybrid Techniques 9.4 Chapter 10: Other Welding Processes General 10.1 Stud Welding 10.1 Arc Stud Welding 10.1 Capacitor Discharge Stud Welding 10.1 Stud Weld Quality Control 10.2 Plasma Arc Welding 10.3 Basic Process 10.3 Variable Polarity Plasma Welding 103 Plasma GMAW 10.4 Arc Spot Welding 10.4 Shielded Metal Arc Welding : 10.5 Oxy-fuel Gas Welding 10.7 Electrogas Welding 108 Electrosiag Welding 10.8 Thermit Welding 10.9 Chapter 11; Weld Performance General 4 Tensiie Strength and Ductility 114 Nonheat-Treatable Alloys W4 Heat-Treatable Alloys 12 Design Properties 13 Postweld Heat Treatment 14 Shear Strength 1.6Chapter 12: Chapter 13: Table of Contents Impact Strength... sn 116 Fatigue Strength a 18 Temperature Effect on Properties ....... _ ie Fracture Characteristics... so ee) Corrosion Resistance : soo 1110 Control of Weld Quality General sos so 2A Testing Methods a 124 Nondestructive Testing : . : 12.4 Visual Inspection ... 12.4 Dye Penetrant Inspection 124 Radiographic Inspection - = 12.4 Ultrasonic inspection : : 122 Destructive Testing - 122 Bend TeSt nenenn ee Fracture Test . : 123 Tensile Test 123 Hardness Test .. 12.4 Metallurgical Examination 12.4 Weld Defects 12.4 Cracks 12.4 Longitudinal Cracks 124 Transverse Cracks 125 Crater Cracks ... ~ 125 Internal Cracks... - 125 Inadequate Penetration . 125 Incomplete Fusion - 126 Porosity 126 Inclusions 127 Undercut 127 Overiap 127 Incorrect Weld Size of Shape. 127 Unsatisfactory Weld Appearance ......-» 129 Design for Welding Gonerat 13.1 Aluminum Properties 13.4 Weight 13.1 ‘Thermal Conductivity and Expansion - 13.4 Modulus of Elasticity : 13.4 Weld Strengths 13.4 Welding Factors Affecting Design iat Accessibility 13.4 Welding Speed : 13.4 Arc Force 13.4 Are Starting ane Termination : 13.2 Edge Preparation 13.2 Joint Fit-Up . . 13.2WELDING ALUMINUM Back Gouging 132 Joint Design 13.2 The Butt Joint so seve 132 The Lap Joint. 132 The Tee Joint. sone — 13.3 The Corner Joint... 13.3 The Edge Joint — : 13.3 Weld Types. ia3 Groove Welds 13.3 Fillet Welds a 135 Plug and Slot Welds : 13.7 Miscellaneous Considerations .....nmuenennnne 13.7 Compensating for Strengtn Loss at Welds 13.7 Doubler Plates 138 Combined Lap and Butt Joints : 13.9 Controlling Weld Distortion 13.10 Extruded Shapes : 13.11 Panel Stiffeners 13.12 Corner Construction 13.12 Intersecting Welds 13.13 GMA Spot Welds 13.13 Brackets and Gussets 13.13 Butt Joints between Unequal Thicknesses. 13.15 Skewed Tee Joints a 13.15 Bulkhead to Shell Joints 13.15 Partial Penetration Groove Welds 13.16 Welds Combined with Mechanical Fasteners 13.16 Designing for Cyclic Loading : 13.16 Welding Costs 13.17 Chapter 14: Resistance Welding General 14.4 Resistance Spot Welding 144 Alloys and Tempers 142 Thicknesses 14.2 Part Fit-up and Weld Spacing 142 Weld Schedules, 143 Electrodes : 143 Weld Size and Strength 14.6 Base Metal Cleaning 147 Welding Machines 148 Discontinuities and Causes 148 Tip Pickup 148 Cracks 148 Porosity 148 Excessive sheet indentation 14.8 Expulsion 148 Penetration 149 Weldbonding 149Chapter 15: Chapter 16: Table of Contents Projection Welding Roll Spot Welding... Upset Welding Flash Welding 7 ea High-Frequency Resistance Welding Current Supplied by Induction Current Supplied through Contacts Solid State Welding General . Explosion Welding... Ultrasonic Weiding Diffusion Welding Pressure Welding Cold Welding «nm. Hot Pressure Welding Friction Welding Friction Stir Welding Related Joining Processes General Brazing Brazeability Filler Metais Fluxes Chloride Fluxes Fluoride Fluxes Torch Brazing Furnace Brazing Induction Brazing Dip Brazing Vacuum Brazing Joint Designs Fixtures Metal Preparation Corrosion Resistance Removal of Chloride Fluxes Soldering Solderability Solders Fluxes Soldering with an fron Torch Soldering Abrasion Soldering Ultrasonic Soldering Furnace Soldering Dip Soldering Resistance Soldering Joint Strengths 149 149 14.10 14.11 14.42 14.13 14.13 15.1 16.4 15.2 15.3 15.4 15.4 15.6 15.6 187 16.1 16.4 16.1 16.2 16.2 16.2 16.3 16.3 163 16.3 165 16.5 16.5 16.5 16.6 16.6 16.6 167 167 167 16.8 16.10 16.10 16.10 16.10 16.11 16.11 16.11 16.12WELDING ALUMINUM Chapter 17: Chapter 18: Chapter 19: Chapter 20: Corrosion Resistance ‘Adhesive Bonding Mechanical Fastening Joining Aluminum to Other Metals General Bimetallic Transition Inserts Fusion Welding with Coatings .... Solid State Welding Explosion welding Ultrasonic welding Diffusion weiding Cold welding Hot pressure welding Friction welding. Flash welding Other Techniques. Brazing Soldering Thermit welding Gas metal arc spot welding Corrosion Resistance of Bimetallic Joints Health and Safety Considerations General Hot Metal Burns Electric Shock. Radiated Light Noise Fume Emissions Smoke Gases Fluxes Cleaning Liquids and Deoxidizers Explosion Codes and Standards for Aluminum Welding General Sources Applications Conclusion Additional Information Sources Chapter 1 Chapter 2 Chapter 3 Chapter 4 Chapter 5 Chapter 6 16.12 16.12 16.12 174 174 74 74 17.2 17.2 472 17.2 17.2 17.2 17.2 17.2 17.2 172 17.3 17.3 17.3 18.4 18.1 18.1 18.4 18.3 18.3 18.4 18.4 18.4 18.4 18.5 19.1 19.4 19.1 19.2 20.4 20.1 20.1 20.1 20.1 20.1Table of Contents Chapter 7 cence 201 Chapter 8... : : 20.1 Chapter 9... . a = 20.2 Chapter 10 = : tee 20.2 Chapter 11 - — : 20.2 Chapter 12.... : 208 Chapter 13. . 20.2 Chapter 14... : i 20.2 Chapter 15 202 Chapter 16 .en . 208 Chapter 17 : 203 Chapter 18 a : 203 Chapter 19 : 203 IndexWELDING ALUMINUM List of Figures Figue # 1.1. Hytogen Sout in Pure Aaminum 31 Ruminur FCC Crystal 32 Etec of Cold Work on Vie Strength of Several Work Hardening loys 33 lsothermal Annealing Curves for $052 that Had Been Gold Worked 8035 34 Relative Crack Sens versus ‘Wiki Composition or Various Binary ‘Aurinum Systms 35 Nonheat-Treatabe Weld (5083 Aly vith 5366 Flt) 36 Hardness Poles Across GTA Wis In Ausrinum loys 8:7 Mirostrsctural Zones in Weds in 6061-T6 Alloy 38 Hardnots Profs in 6061-76 GTA Welds ‘th Vanous Heat Inputs 39° Typical Hot Cracking ina Welded Ag Alloy 3.10 Liquation Craking hind a Weld in an AMS Aloy 44 Micto-Cracking in Plasma Are Cut Ege in Auminan 42 Laser Cuting 43 Cutting Aluminum Extrusion with Creviar Saw 44 Tooth Spacing of Bades 45 Some Typical Disos 48 Rotary Cuter Gouging Mactine fr ‘Ain 47 Chisel Shape for Preurate Gouging ‘9 Alurinum 48 Planing Edge of Plate 49 Bevelng with a Joiner 5.1 Back Gouging Recommended Groove Shapes 52 GMAWeld wih Smt 53 Weld Smut Compostion 54 Reationsia elds to Nevtal Axes 'o Minimize Oisorion 61 ‘Schematic Diagrams ofthe GTAW Process 6.2 GTAW Process wih Added Fler 63 Typical Jot Geometries for AC-GTAN cl Weding Aluminum 63M Typical Joint Geometries fr AC-GTAMY of Weng Amine 64 Exiended-Lard Bove 65 Advantages of Etended-Land Seve 65 Typical Jot Geometries for OCEN-GTAW cf Auninur 564 Typical Joint Geometries fr DOEN-GTAW of Alanna 71 Schematic Diagram othe Semiautomatic GMAW Process Page # 12 32 33 33 36 313 ana 305 315 316 2 44 44 45 45 46 46 45 47 52 61 65 56 67 613 eid 615 618 n Foust 2 73 7 75 78 17 me 84 82 83 a4 a 92 93 94 95 96 a7 98 104 CCuren-votage Characteristic ot a Drooper Power Source CCuree-vltage Characteristic ofa Constant Votage Power Source Voltage and Curent Tacs for Pulsed aw Longtusna sections through high curent welds made with CC and CV power supptes GMAW Blectode Wire Feeder Systems Eet of Argon and Helium Sheng Gases on Weld Fusion tape “gies! GMAW Joint Georetes fr Semiautomatc Welding of Aluminum “pical GNAWJiet Geometis or ‘Semiautomatic Welding of Aluminum ‘Semiautomatic GMAW Process (Gross Sectons of Weld Stops Schematic Diagram ofthe Auras GMAW Provess Beveled Nozze for Automatic GMAW wih Helm Shielding Gas ‘Schematic ofthe Electron Beam Welding Process Alunioum Piston Weed with Pulsed ea CComparson of High-Yacwum and Partainon-vacuum Electron Beam Processes ange Weld of 25mm AASTS4 Stuctual Beam Box Schematic of Lager Beam Welding Schematic of a CO, Laser 0, Laser Schematic oa We YAG Laser NAYAG Laser Beam Configurations for Laser Welding of Alumoun Aloys tot mounted Direct Diode Laser Plasma-augmented CO, Laser Weting with Wire Feee Tworpass, Verbal Pasion Variable Plty Plasma Are Weld in 12-inch (12.7 mam) Thick 2510-787 Imergranuiar Cracking ina 2014-76 Forging HAZ “ypicai Shear Srengins of Longitudinal Filet Welds “pica Shear Strengis of Tarsvese Filet Wes Fatigue Svenghs of GMAW Butt sboints Relate Toughness and Tear Resistance Ratings of Aluminum Alloy Welimerts Page # 7 73 14 78 78 710 ma 738 78 719 720 82 82 a 92 92 93 94 ad ny Ne 1110WELDING ALUMINUM Figue # 12.1 Mechanism for Wrap-Around Bend Test 122 Cracking in Groove Weld When Reverse Side Bead Overpenetrates Face Side Bead 123 Heat Afected Zana Cracking 124 Cracking al WeldBase Metal inerace (6013-75 GTA Weed with 556 Filer) 125 Worm-Hole Posty 126 Acceptable and Unacoeplabie Weld Proies 13.1 Typical Groove Weld Geameties 132 Typical Joint Geometry for Tbe 12 Tube-Sheet Weld 133 Extended Land Bove for Welding Alunioum Pipe 134 Reiniomement Shape on Faigue Strength Groove lis 135 Shape of Filet Weds 136 Concave, Convex ard Unersal Leg Fit Welds 137 Cast Advantage of Edge Prepared Filet Welds 138 Slot Welds 139 Example ofa Weld at Neutral As of Beam 18.10 Common Design Alonarce for Reduced Stenghn at Weds 18:11 Reinforcement of Welded But Joint 1312 Combining Lap and But Joint 1013 Groove Welds in Exrusion with integral Backing 3.14 Bulbon Extruded Flange for Improved Weiaatlty 13.15 Offset Fange on Extusion 1316 Welds on Lap soils 13.17 Interlocking Faces on Exrusons Pap 123 125 125 126 126 128 134 134 134 135 135 136 137 138 138 138 139 310 ran nase wae 1312 Fue # 18 1318 1320 1321 1322 1323 1324 1325 1326 1327 1328 a 42 143 144 45 181 152 153 84 55 156 181 162 ‘Sloted Extusons fr Welding to Steet ‘Components Pana Sitinars| Tapered Ends on Sitioners Fed Ens on Siienars Typical Comer Constructions intersecting Welds Bractats 0 Gussels Too soits at Other Than ight Angles Bulkhead to Shel Joints Combining Welding and Mecharical Fasteners lutte Examples of Twenty Geometis Less than Minimum Overap and Poor FitUp Resistance Spot Welding Tip Dressing Too| Determining Button Diameter (0+ d'2 High Frequency inducton Welding High Frequency Resistance Weng ‘ATypcal Explosion Weld in Aluminum CContiguratins for Expiosion Welding “Typical Cold Wed in 18h (3.2m) Diameter 6201 Alo Wire “Typical Indertr Coniguraons Used for oi Welding Relationship Between Welding “Temperatue and Welding Pressure at (Optimum Deformation - Lap Jont Friction Sti Welding ‘Automobile Radiator Core Brazet with Fiuorde Fux ina Nivogen Aimosphere of a CContrvous Furnace Utasoni Dip Slsered Return Bend pints of Air ondioning Condenser with High Temperature Zinc Soder Page 13.12 1313 1303 1313 rats 34 1318 1315 13.16 1318 143 143 147 a rane 151 152 154 1! 156 187 187 18WELDING ALUMINUM List of Tables Tablet 24 22 26 27 28 29 210 ant 212 34 32 33 35 36 4a 61 62 sam 63 64 ean Page # Designation Systm for Vrought 22 Aluminum loys | Designation System or Cast 22 ‘Alurinum aloys Subhisions of H Temper: Stain 28 Hardones Subchisions of Terper:Thermaly 2 Treated CCompostions and Aopications of 2a NorheaTreatale Wrought uminum Aloys Composers ard Applications of 25 Heat Teaable Wrought Aiurinum Alloys Weidebity and Properties of Nooheat- 26 “ralabe Wrought Auinum Aloys Wildabity and roportos of Heat 27 Treated Wrought Aluminum Aloys Compositions. ypes and appications of 2 NoreaiTreatale Cast Aluminum Aloys Compson. Types and Applications af 2.10 eat Testable Cast Aluminum Alays Wieldebily and Properties of Nonbeat- 2.1 Teatate Cast Aluminum Aboys Wieldaity and Propertes of Heat 213 “Teatabie Cast Auminum Alloys ayimum Sof Salty Aiumiqum of Pini laying Adtions oniral Campostons of Commen Weidabis 32 Wrought Aluminum Aloys 'Nomnai Gampostons of Common Welcsb Cast Aluminum Aloys Casing Types, Hea-Testbity and 38 Wildabity of Common Aluminurs Cas Aloys Nominal Cerestons of Comeron Aluinum Filer Aloys Guide ta Choice of Filer Meta for General Purpose Welding Typica Plasma Arc Cuting Prooadures 42 ‘or Aluminum Curent Ratings or Tungsten Eectroses 6.4 for AC-GTA Welding vith Argon Typical AGT Procedures x Grove 65 cng Aurinurs “Typical AC-GTA Procedues for Groove 6.9 Welding Aluminum “pica AC-GTA Procedures lor Lap 610 Welding Atsrinum “Typical RC-GTA Procedures for Lao en Wearg Aluminum “ical AC-GTA Procedures for Edge and Corer Welding Aluminum “Typical AC-GTA Procedures for Edge and 6.12 Corer Weleng Auminun Table 65 Typical Direct Curont Ranges or Tungsten Electtodes 68 Typical DC (EN}-GTA Procedures for Heanual Groove Welting Auminum GEM Typical DC (EN-GTA Praedues for Manual Grave Welding Aluninum 67 Typical OC (EN-GTA Procecures for anual Filet Lap Welding Aluriaurn “pica DC (EN}-GTA Procedures for ‘Manual Filet Lap Weisng Aluminum 68 Typical Procedures for Autor DC (EN}GTA Welding Square Gove dans in 2219 Alumina “pica! Paves for Automatic 1G (EN-GTA Welding Square Groove Joins in 2219 Aluminum 71 Typical Semiautomatic GMAW Procedures or Ginove Welding Aluminum 7 VM Typeal Semiautomatic GMAW Procedures for Groove Welding Auminum 72 Typica Semiautomatic GMAW Procedures for Filet and Lap Welding Atuminum sam 72M Typical Semiautonatic GMAW Procedures foc Filet and Lap Welaing Aluminum 73 The tfc of rc Length on Spray Teansfor GMA Welds 74 Thermal Conducts of uinum Alloys 10.1. Typal Are Stud Welding Procecures 102 Stengtho are Weld Sxax Series Stud Heiss 103 Strength of Capactor Discharge Welds xx Series Studs ‘As Welded Traneverse Tenle Properties 6! Groove Welds by Several Welding Processes in inch (127 mem) 2219-7877 King Conditions fr Shielded 108 Welng Fux Removal Metheds 107 Approximate conatons for Ony Fuel Gas Weng 111 Macharical Properties o Gas-Shielied ‘rc Welded Bull Joins in Nonfat Treatable Auminum Aloys 112 Typeal Mechanica Properties of Gas Sitieded Arc Welced But Joni in Heat “Toate Aluminum Aloys “ical Mecharicl Properties of Gas Shielded Arc Welded But Joints in Heat THeatabie Aurinum Aloys 11:3 Comparing Properties of $089 and 6061 loys col Welding Cordis an 6061 Wieldea Stang wth 4943 Filet Ect of Welding Condtons on 6061 ‘Wetded Strength wth 4049 Fler sam Pane ¢ oy 68 616 ea err 618 619 ne 104 102 102 104 13 M15 116WELDING ALUMINUM _ Tiled 5 118 116M 131 132 at 142 143 44 145 Minimum Shear Srenghs of Filet Welds timate Tensile Stenath at Varous Temperatures of Groove Welds in Aluminum Aloys timate Tensie Strength at Various Temperatures of Groove Welas in Auninum Aloys Mande Diamar for Bend Testog ‘unin Groove Welds ‘Aowable Stess Range, kl (MPa) ‘Stress Category Resistance Spo! Wed Size, Spacing, Edge Distance, Contacting Overt Typeal Spot Welding Schedule for Commercial Applications Typcal Single Phase AC Spot Welding Schedule “ypcal Single Phase AC Spot Welding Schedule with Slope Conrl “Typical Tiree Phase Conertr Spot Page # 18 19 123 1317 1319 142 44 145 145 46 Tiles 148 7 148 181 161 182 183 ee 165 168 187 it Welding Schedule Typical Three Phase DC Rein Spot ‘ilcing Schedule Typical Sear Strength Requirements for Spot Waids ‘Typical Rol Spot Welding Schecuies Typical Stengths of Utrasonic Spt Wels in Aluminum Common Brazing Filer Alloys and Forms Some Standard Brazing Sheet Prous Brazing Combinatons wih Various Pures ‘Chemical Prereatments fr Aluminum to Be Brared Fx Removal Solutions Cassicaton of Aluminum Soiders CComposions, Moting Ranges and Properties of Common Aluminum Solders ‘Guide for Shade Numbers Page # 146 47 4s 153 182 163 184 186 188 169 169 182WELDING ALUMINUM Chapter 1: Introduction to Aluminum Welding Superb strength-to-weight ratio, immunity to corrosion, and intrinsic recyelability render alu- minum and its alloys desirable for many: manue facturing applications. But to be competitive in the modern industrial world, a structural meta! must be readily weldable. ‘The earliest welding techniques suitable for afuminum included oxy-fuel gas Welding and re- sistance welding, Are welding of aluminum was mainly restricted to the shielded metal are process with a flux-coated electrode which created corto- sion problems when the flux was inadequately moved. The breakthrough for aluminum as a struc- ‘ural metal occurred with the mtroduetion un the 1940s of the inert gas welding processes. such as Gas Metal Are Welding (GMAW. also referred to as Metal Inert Gas or MIG) and Gas Tungsten Are Welding (GTAW, also referred to as Tungsten In- ert Gas or TIG), It became possible fo make high strength welds without corrosive fluxes at by is and in all positions Today. aluminum and its alloys are readily weldable using a variety of techmques. This book will thoroughly explam the traditional joming methods for aluminum. such as GMAW and GTAW, and will introduce the lates? éechnologies, such as laser Welding. This book 1s dedicated to exposing North American industry 0 up-to-date knowledge of aluminum welding so that full ad- vantage may be taken of the unigue and beneficial properties of this usefull metal Welded Aluminum Applications Aluminum and its alloys are highly sumtable for many manufacturing applications. Aluminum alloys have prevailed in the aerospace dustry since its inception, Aluminum 1s used for a wide e of aerospace applications from racket eas 10 spave station modules, Today the automotive industry. faced with mnereasing demands for fuel economy. has seri- ously begun 10 incorporate aluminum alloys mto vehieles. Integration of aluminum alloys in elo~ sures, body structure, and frames provides desired hight-weighting without compromising perfor- vhway truck bodies and some cabs are fabricated of welded aluminum, provid- ing larger capacities without adding to gross ‘weight, Fire engines are also but of aluminum to reduce weight and improve performance. Overhead highway signs, lighting poles and protective railings are common on our highways. Aluminum for these applications offers ood! ap- pearance, durability. and ease of handling during assembly. A growing number of eorrosion-resistant gon- ola rail cars is being built for service in the trans Portation of coal and other bulk commodities, Pas- senger vehicles for inter-city rail serviee. rapid transit, subway systems and for spectatized people movers are commonly of welded aluminum. The marine uses of aluminum include al! types of work and pleasure craft as well as spe~ ctalized mibtary eral, In addition, there are many ‘unusual applications sich as helicopter recovery systems for marine vesse! Welded aluminum pipelines are used where the corrosion resistance. weldability and other tunigue properties of aluminum are beneticial for transporting otl. gas. water and wiher chemical products. The use of welded aluminum 1s also preva- lent im other industries such as electromies. pack- aging. and architecture. There are numerous ex- amples of the advantages of aluminum fabricated by welding, Just afew of these are temporary burld- angs. glass houses for plant nussevies. pedestrian, bridges. specialized architectural components and storage tanks. Aluminum's Properties Contrary to popular behef, aluminum alloys are not difficult to weld. However, aluminum ale loys have unique ehacactersties that must be con- sidered for successful young, Chemical Properties Aluminum alloys are highly susceptible to hydrogen porosity during fusion welding. Sources of hydrogen inelude water. die and selling lubr. ccants. and air Hydragen dissolves readily unto the motien weld pool and produces gas pores upon solidifjeation. as shown in Figure 1.1 Hydrogen 171WELDING ALUMINUM porosity ean be avoided by using proper gas shield- ing during welding, keeping the aluminum clean and dry, and avoiding temperature fluctuations that lead to condensation. ‘Allaluminum alloys have a thin but tenacious surface oxide. This oxide layer can be removed mechanically or chemically, but it immediately reforms. The essentially instantaneous thickness is about 15A, but the subsequent growth rate de. creases so that on normal metal the oxide thick ness may be 25-50A. (An angstrom, A, is about 4 billionths of an inch.) While the oxide layer is extremely thin, it suicient to protect the metal against further oxid tion as well as most corrosive attacks. For extra protection or for certain other benefits. such as decorative coatings, the surface may be anodized to produce much greater thicknesses (1000 times (or more). Thermally treated metal also has a thicker oxide. The oxide is very hard, being the hardest ‘material after diamond, For this reason aluminum oxide is often used for the grit in grinding wheels, The melting point of the oxide is 3725°F (2052°C), which is about 3 times that of aluminum, The ox- ide is relatively stable and chemically inert: fluxes to remove it normally contain chloride and fluo- ride compounds and consequently pose a continu- ing corrosion hazard to the metal ifnot completely removed after joining, The oxide is an electrical insulator. Normal oxide thicknesses are not sufficient to prevent initiation of an electric welding are. but anodizing may produce a film thickness that prohibits are welding The surface ofaluminum ox- ide is quite porous. and it can re- ‘ain moisture or contaminants that may result in weld porosity. This, is especially true of alloys coatain- ig Magnesium because magn: sium oxide or magnesium-alumi- ‘num oxide readily hydrates. Thus, it is good practice to keep alumi- num clean and dry and to avoid temperature fluctuations that lead to condensation. Metal stored in the presence of high humidity and fluctuating temperatures may grow a thick oxide called a “wa- ter stain.” This thick. contami nated oxide should be removed H SOLUBILITY e009) prior to welding since it ean introduce hydrogen and other contaminants into the weld pool. Physical Properties Aluminum is light; it has roughly one-third the weight of steel. Pure aluminum melts at 1220°F (660°C), which is less than one-half the melt point for steel. Thermal conductivity is about 6 times that of steel, which means that the heat to produce melting must be more intense for efficient welding. Thermal expansion is about twice that for steel and solidification shrinkage is 6% by volume, inereasing both distortion and weld era ter size. Aluminum's electrical conductivity is high— about 65% that of pure copper. Aluminum does not change color as itis heated, which means care has to be taken not to touch what appears to be cold metal, Aluminum is non-magnetic. This elimi- nates problems of “are blow.” but it also means that magnetic lifting devices are not effective. Mechanical Properties Pure aluminum is a weak but highly ductile metal. However. by alloying with one or more cements, the stre still retaining acceptable levels of ductility. The modulus of elasticity is approximately 10.000.000 psi (70.000 MPa). which is one-third that for steel ‘Thus, for the same applied force aluminum de- fleets three times more than steel. which gives it the ability to absor’ greater energy under impact loadings, TEMPERATURE _ Sokbity in Lu a Moting Pont Soksity in Sot ‘TEMPERATURE * Figure 1.1 Hydrogen Solubility in Pure AluminumChapter t: Introduction to Aluminum Welding Aluminum’ toughness is not compromised al low temperatures. In fact, ductility increases as the temperature decreases, down to cryogenic tem- peratures Forms of Aluminum Wrought aluminum is available in a wide range of forms, including sheet. plate, foil, rod. bar and wire. It can also be extruded into a variety ‘of products such as structural shapes (angles, chan- nels, T's, Z's, H-beams, I-beams) and into pipe aad tubing. The metal can be forged for products uiring the unique properties afforded by forgings. Aluminum castingsare also very common. whet sand cast, permanent mokt castor vacuum die: depending on the product requirements. Sheet and plate can be clad with aluminum of different alloys to obtain supetior corrosion re- sistance or for brazing filler metal. Almost any form that can be conceived is possible. Indeed, even aluminum joined to other metals such as steel, stainless steel and copper is available for special applications. shWELDING ALUMINUM Chapter 2: Alloy and Temper Designation Systems Pure, unalloyed aluminum is a sofi, ductile metal with excellent corrosion resistance and good electrical and thermal conductivity: Because al ‘minum makes a good vapor barrier, it js an excel- lent packaging material. As plate. aluminum is used for the storage and handling of some chemicals. As wire. it is used for transmission cable, How- ‘ever, as pure metal, itis not strong enough for stru tural applications, ani thus most aluntinum is al loyed to obtain the needed properties. Most alloys are solid solutions of one or more elements dissolved in the aluminum base, These solid solutions are usually strengthened further by sttain hardening or by heatetn A designation system for bath the alloy eon position and rts temper has been developed by the Aluminum Association and is now in common use throughout Novth America and in many other areas OF the world, New alloys. as they are developed, are registered with the Aluminum Association. which assigns them to the appropnate series and azives them distinctive numbers so that they ean be readily identified by both producer and user Information on the active aluminum alloys 1s contained in a series of documents published by The Aluminum Association. The Aluminum Asso- ciation also publishes a number of handbooks that contain chemical composition limits and other data for commonly used alloys. These publications are sted in Chapyer 20° Additional Information Sauces. Below 1s a summary oF the mformation for those who need only a basic understanding of the alloy designation system, The temper design tion system will be described later in this chapter Alloying Elements The principal alloying elements are copper (Cu), manganese (Mn). siligon (St), magnesium (Mg) and zine (Zn), Other elements are addec in smaller amounts to aet as grain refiners oF 10 pro= duce special properties. A further group of un- wanted elements, found in trace amounts 1m alu minum and aluminum alloys. has no benefieral effgets. Those elements are termed impurities A recent development 1s the introduchen of lithium (Livalloys for structural applications where their lower density: higher strengths and higher modulus of elasticity cas be beneficial, They also contain capper (Cu and in some cases magnesium {Mg and are classified either in the 24xx oF Sxxx series depending on which alloying element is dominant Wrought Alloy Designations A four-digit number is used to designate each ‘wrought alloy. The first digit indicates the prine pal alloying element or elements. Table 2.1 shows the assignment of the numbers | t0 9 far these el- ements, For example. the Lxxx series is For essen tially pure gluminum and the 6xXx series is for atioys using the combined effect of Mg and Si Having established the alloy series by the frst digit, one can obtain additional information from the remaining three designation numbers. The se ond digit, different frone 6, denotes a modifie tion to the originally registered alloy. The third and foutth digits form an arbitrary number identi- ications and with the assigned alloy number Alloy 5154 1s the same alloy after modifi- cation. The ane exception to this use of the third and fourth diguts is the INxx semes. which for cessenttally pure aluminum, In this series the third and fourth digats indicate the degree of purty of the aluminum above 99.004. by disclosing the first ‘wo decimal points. For exemple. alloy 1060 has a mimmunt oF 99.60% aluminum, Cast Alloy Designations A three-digit number plus one deeimat is used to designate each cast alloy: The first digit indie eates the priberpat alloying element or elements. Table 2.2 shows the assignment of the numbers to 9 for these elements. Again the Lxx.x series is for essentially pure aluminum. The others Follow the same general pattern as the wrought alloy sys: tem but with some significant differences, so care ‘most be taken st using the two systems, The cast alloy designations lack the modtfi- cation digit of the wrought alloy des stead. moxificanions are indicated by a prefix let= ter(A.B.C. ete}. The second and third dizes formWELDING ALUMINUM Table 2.1 Designation System for Wrought Aluminum Alloys. Alloy Series Principal Alloying Element ‘ee ‘Aluminum, 99.00% minimum and grater 2x copper Sox Manganese 0% Silicon 50x Magnesium Box Magnesium and Siicon Tox Zine Box Other Element 80x Unused Series Table 22 Designation System for Cast Aluminum Alloys Alloy Series ringipal Alloying Element vmx Essentially pure aluminum Dex Comper Bex Siicon plus Copger andlor Magnesium oxx Slicon 5exx Magnesium 60x Unused Series Tex Zine Bxxx Tin Sex Other Element the arbitrary number identifying the specific alloy or for the Ixx.x alloys give the degree of purity above 99.00% in the same way as described above for wrought alloys. The decimal indicates whether the alloy composition is for the final casting (.0) or for ingot (| or 2. depending on impurity lim- iss). An example of a typical silicon ma alloy for final casting is 356.0 and the same al- loy in ingot form would be either A356.1 of A356.2, 22 Temper Designations Some aluminum alloys achieve temper by strain hardening and some by heat-treatment, In general, the Lxxx, 3xxx, 4xxx and Sxxx series ‘wrought alloys are strain hardenable. The 2xxx. (6xxx and 7xnx series wrought alloys.ate heat-treat- able, The 2xx.x, 3xx.x.4xx.x and 7R%.X series cast alloys are heat-treatable. Strain hardening is not generally applied to castings, ‘The basic temper designations are: “Fas fabricated. Applies to products of Forming processes in which no special control over thermal or strain hardening conditions is employed. Mechanical property limits are not assigned to ‘wrought alloys in this temper but are assigned to cast alloys in the “as east"(F) temper. “0” annealed. Applies to wrought and cast products that have been heated to produce the low- est strength condition and to improve ductility and dimensional stability. H” strain hardened. Applies to wrought products that are strengthened by strain harden- ing through cold working. The strain hardening may be followed by supplementary thermal treat ment. which produces some reduction in strength, The “H” is always followed by two or more dig- its. See Table 2:3. “W" solution heat-treated. Applies to an unstable temper applicable only to alloy’ that age spontaneously at room temperature after solution heat-treatment. This designation is spevitie only when the period of natural aging is specified: for example. W Yh. Solution heat-treatment involves heating the alloy to approximately 1000°F (538°C) to bring the alloying elements into solid solution followed by rapid quenching to achieve a super saturated solution at room temperature thermally treated to produce stable tempers other than F,O or H. Applies prod- ucts thatt have been heat-treated, sometimes with supplementary strain-hardening. to produce a stable temper. The T is always followed by one or mote digits. See Table 2.4