Dewan 2015

Journal of Manufacturing Science and Engineering.
Received December 10, 2014;

Accepted manuscript posted April 8, 2015. doi:10.1115/1.4030333
Copyright (c) 2015
Journal by ASME Science and Engineering
of Manufacturing
Influence of Weld Defects and Post-Weld Heat Treatment (PWHT) of Gas Tungsten Arc
(GTA)-Welded AA-6061-T651 Aluminum Alloy
Mohammad W. Dewan
Graduate Student
Department of Mechanical & Industrial Engineering
2508 Patrick F. Taylor Hall
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Louisiana State University and A&M College
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Baton Rouge, LA 70803
E-mail: mdewan1@tigers.lsu.edu
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¹
M.A. Wahab
Professor
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Department of Mechanical & Industrial Engineering
2508 Patrick F. Taylor Hall
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E-mail: wahab@me.lsu.edu
Ayman M. Okeil
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Associate Professor
Department of Civil & Environmental Engineering
3513E Patrick F. Taylor Hall
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E-mail: aokeil@.lsu.edu
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ABSTRACT
Welding defects and the reduction of mechanical performances are the foremost problems for fusion welded
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aluminum alloys joints. The influences of weld defects and post-weld heat treatment (PWHT) on tensile
properties of gas tungsten arc (GTA) welded aluminum alloy AA-6061-T651 joints are investigated in this
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current study. All welded specimens are non-destructively inspected with phased array ultrasonic testing
(PAUT) to classify weld defect and measure the projected defects area-ratio (AR). Ultimate tensile strength
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(UTS) decreased linearly with the increase of the size of weld defect but tensile toughness behaved non-linearly
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with defect size. Depending on defect size, defective samples’ joint efficiency (JE) varied from 35 to 48% of
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base metal’s UTS. Defect-free as-welded (AW) specimens observed to have 53% and 34% JE based on UTS
and yield strength (YS) of base metal, respectively. PWHT was applied on defect-free welded specimens to
improve tensile properties by precipitation hardening, microstructures refining, and removal of post-weld
residual stresses. Solution treatment (at 540 °C) followed by varying levels of artificial age-hardening time was
investigated to obtain optimum tensile properties. For GTA welded AA-6061-T651, peak aging time was 5
1
¹
Corresponding author: M.A. Wahab, E-mail: wahab@me.lsu.edu, Tel.: +1-225-578-5823; Fax: +1-225-578-5924.
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Journal of Manufacturing Science and Engineering. Received December 10, 2014;
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hours at 180 °C. PWHT specimens showed 85% JE based on UTS and up to a 71% JE based on YS of base
metal. However, toughness values decreased about 29% due to the presence of precipitate-free fusion zones.
The experimental investigations can be used to establish weld acceptance/rejection criteria and for the design of
welded aluminum alloy structures.
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Keywords: Aluminum alloy; Weld defects; Tensile properties; Phased array ultrasonic testing; and Post-weld
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heat treatments
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INTRODUCTION
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Heat-treatable AA-6061-T651 Aluminum alloy (Al-Mg-Si) has found wide applications for its weldability
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advantages over other high strength aluminum alloys [1, 2]. Fusion welding of Aluminum and its alloys is
always a great challenge for designers and technologists due to the intrinsic problem of porosity in aluminum
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welding and its eventual strength reductions. High coefficient of thermal expansion of aluminum, solidification
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shrinkage, and high solubility of hydrogen during its molten state creates associated problems during fusion
welding of aluminum alloys [3, 4]. As a consequence, weld defects are quite common, which result in the lower
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mechanical properties in aluminum alloys joints. The weld defects can be in the form of surface or sub-surface
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cracks, undercut, porosity, or sub-surface inclusions. The failure of welded structures generally start from
preexisting weld defects [5] which are intrinsic to the fusion arc welding processes. An important decision
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relating to its structural integrity must be made regarding weld defects and their effects on the strength of
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welded components. Only a limited number of studies have been reported in the open literatures on the effects
of weld defects on mechanical performances [6-9]. Rudy and Rupert [7] and Lawrence et. al. [8] studied the
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effect of porosity on welded AA-2xxx and AA-5xxx aluminum alloys, respectively. Morton [6] showed a linear
relationship between fracture strength and projected defect areas of GTA- welded AA-2xxx aluminum alloys.
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However, no conclusive study reported on weld defects and their effects on GTA- welded AA-6xxx aluminum
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alloy. A relation between non-destructively evaluated weld defects and tensile properties can help in designing a
welded structure efficiently. A reliable non-destructive evaluation (NDE) method is required for defect-sizing
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and correlation with tensile properties of welded specimens. Phased array ultrasonic testing (PAUT) is
relatively a new and challenging NDE technology that can be employed effectively for weld defect sizing [10,
11]. PAUT offers increased inspection sensitivity and coverage, straightforward visualization, and simplifying

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data interpretation of weld defects [12-14]. By utilizing PAUT, the operator is better prepared to determine the
size, shape, and orientations of weld-defects [15, 16].
Besides weld defects, residual stresses and microstructural changes are the two other key factors for
performance reduction as well as failure of welded heat treatable aluminum alloy joints. During welding
process, exposure to high temperature fusion followed by non-linear rapid cooling near the fusion areas cause
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grain coarsening and post-weld residual stress development in the heat- affected- zone (HAZ) and fusion zone
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of the weld joint [17]. In some cases, multipass welding is required to join two pieces. Multipass welding causes
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strain hardening during the heating and cooling of subsequent passes. The strain hardening has a significant
influence on the residual stress development in the weld zone [18]. Zhao et al. showed that the residual stresses
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of a multipass weld joint decreases with the increase of deposition pass number and idle time between each
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layer [19]. Due to welding heat, the materials in the HAZ and fusion zone effectively becomes softer and more
susceptible to failure [20]. Different post-weld treatment techniques are usually applied to improve mechanical
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performances of heat treatable aluminum alloy joints. A number of research studies have investigated the
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application of post-weld heat treatment (PWHT) to different aluminum alloy welding joints using several
welding processes [21-32]. But only a few investigations showed the effect of PWHT on fusion welded
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AA6061 aluminum alloys [21, 30, 31, 33]. PWHT technique and strength of GTA-welded aluminum alloy
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joints are largely depend on filler metals. Among different filler metals, AA-4043 filler rod is widely utilized in
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GTA welding of aluminum alloy AA-6061 [34, 35]. When 4xxx series filler metal is employed, the weld zone
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doesn’t respond to only post-weld aging as sufficient magnesium is not present for the precipitation of Mg2Si,
which is the main strengthening phase. However, these welds respond to solution treatment followed by aging
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(STA). PWHT contributes to precipitation of alloying elements, grain refinement, and higher dislocation density
in welded AA6061 aluminum alloys; and consequently enhanced mechanical properties that can be achieved
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[26, 36, 37]. The thermal treatment for aluminum alloy AA-6xxx series consists of two main processes: solution
heat treatment and age hardening [38, 39]. During the artificial aging process solution treated material is kept to
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a specified temperature for an extended period of time, depending on the type of material being used, and the
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types of precipitates existing within the materials. Exposing the material to a temperature for longer than
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required aging time, can cause the precipitates to grow too large and more widely dispersed within the material
[40]. This effect causes the material eventually to lose its strength. Therefore, optimum aging temperature and
time are essentially required for PWHT process to obtain improved mechanical properties.
From the critical reviews of the available literature, it is understood that few research efforts have been
published on the effect of weld defects and PWHT on AA-6061-T651 joints using GTA welding method. The

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primary objective of this work is to obtain tensile test data for GTA welded aluminum alloy AA-6061-T651
joint containing specific flaws and to correlate these data with the nondestructive phased array ultrasonic testing
(PAUT) results. Tensile test data are also correlated with microscopic evaluation; and a comparison is made
between these two inspection methods relative to the evaluation of weld discontinuities. The present
investigation also included the influence of PWHT on mechanical properties of GTA welded aluminum alloy
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AA-6061-T651 joint.
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MATERIAL AND WELDING PROCESS, AND EXPERIMENTAL PROCEDURES
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Materials and welding process
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Rolled plates of AA-6061-T651 aluminum alloy with 300 mm × 76 mm × 6.35 mm dimensions are GTA-
welded utilizing ER- 4043 Aluminum alloy GTA welding filler rod according to AWS D1.2/D1.2M:2008 . The
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specified chemical compositions (by wt. %) of the base metal (BM) and filler metal (FM) are presented in Table
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1 [41]. There was a root gap maintain between two plates to be joined. The gap between two plates helps to
expand the arc plasma and transfer metal [34]. The direction of welding was normal to the rolling direction and
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all necessary care was taken to avoid joint distortion while clamping the plates at suitable positions. Multipass
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welding was used to fabricate the butt joints. An inert gas mixture of Argon/Helium (50/50) was used as
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shielding gas as this mixture helps in the constriction of the arc and concentrates the heat within a restricted
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weld nugget area, thereby reducing the size of the heat- affected -zone (HAZ) [42]. The welding speeds were
calculated manually from the time required to weld a particular length and maintained in the range of 60 - 70
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mm/min. Welding peak current varied from 120 amps - 140 amps. Welding was followed by natural air cooling
at room temperature (25 °C) and grinding afterwards. All the welds performed were visually and ultrasonically
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inspected for possible defects. The “dogbone” tensile test specimens were cut from welded plates according to
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ASTM E8/8M-11. The Fig. 1 shows the schematic diagram of weld groove and the configuration of the
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dogbone tensile samples.

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Experimental Procedures
Each dogbone specimen was inspected with Olympus “Omniscan MX2.0” nondestructive phased array
ultrasonic testing (PAUT) unit. Angle beam wedge (30° - 70°) with 5 MHz, 16- elements linear phased array
ultrasonic probe was used for the PAUT inspection. Before inspections, the PAUT probe and wedge were
calibrated with standard calibration blocks made of the same material to be inspected. PAUT calibration

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included velocity, wedge delay, sensitivity, and sizing calibration. After conducting the nondestructive PAUT
inspection, the specimens were classified into four categories according to the types of defects detected (no-
defect, voids, lack of fusion (LOF), and lack of penetration (LOP)). The defects were formed due to the
variations in welding conditions, welding process parameters, and control during manual fusion welding
process. Lack of penetration (LOP) is usually caused by the use of too low welding current. Other causes can be
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the use of slow travel speed and narrow root gap. Lack of fusion (LOF) is generally caused due to low welding
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voltage and low welding speed. Multipass welding can also result in LOF and porosity, which are usually
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caused by entrapped gases in between the subsequent passes. The porosities are mostly formed due to
inadequate shielding gases during the welding process.
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Post-weld heat treatment (PWHT) was performed to improve tensile properties of welded specimens. For
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rational comparison, PWHT was accomplished on defect-free welded specimens. To study the effect of artificial
Age-Hardening (AH), welded and naturally cooled specimens at room temperature were placed into
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conventional oven at 180 °C for 10 hours followed by air cooling at room temperature. For Solution-Treatment
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(ST), as-welded specimens were placed into conventional oven at 540 °C for 1.0 hour followed by quenching
into cold water (4 °C). Subsequently, artificial AH was investigated on ST- samples to obtain peak aging time.
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Aging temperature was 180 °C and aging-time was varied from 3 hours to 18 hours. Solution Treatments
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followed by Age- Hardening specimens are named as STAH.

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Uniaxial tensile test specimens were prepared and tested according to ASTM E8/8M-11 at 1.2 mm/min
cross head speed in an MTS- 810 universal testing machine. The tensile strain was measured using a 25.4 mm
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(1″) gage length extensometer that was attached to the middle of the specimen near the weld zone. All test
results were computed based on statistical sample of six specimens. The yield strength was obtained employing
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the 0.2% offset yield strength method. Toughness value was calculated from the area under the tensile stress-
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strain curve. For verification, base metal toughness value was compared with values found from the literature
and it was analogous [41]. Tensile test specimens were cut along the cross section to measure the actual defect
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sizes using a Leica MZ75 Optical microscope (OM). Projected cross sectional “area-ratio” was calculated by
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dividing the cross sectional areas of defect with the original cross sectional area of the sample. Fracture surfaces
of the tensile tested specimens were analyzed with a Quanta 3D FEG scanning electron microscope (SEM). For
better understanding of the effect of PWHT, the hardness across the weld surface was measured using Rockwell
hardness tester (Type: FUTURE-TECH Rockwell type hardness tester, Model: Digital FR-3e) with 1.58 mm

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(1/16 inch) diameter steel ball indenter along with 15 kg load (HR 15T scale). Before using micro-hardness
tester it was calibrated using appropriate calibration block.
RESULTS AND DISCUSSIONS

Effects of weld defects
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Using PAUT one can find the A, B, C, and S scan views to find size, shape, and location of defects. Fig. 2
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shows the C-scan and S-scan views obtained from PAUT of dogbone specimens before they were tested. The
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specimens were chosen to have different types of weld defects. C-scan is a two dimensional presentation of data
displayed as a top or planar view of a test piece. S-scan or sectorial scan image represents a two-dimensional
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cross-sectional view derived from a series of A-scans that have been plotted with respect to time delay and
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refracted angle. The horizontal axis corresponds to location of the defect from probe position, and the vertical
axis to depth of the test piece. If there is a defect present within the scanned samples, it can be visualized in 6
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dB color palette in different scan views (B, C, and S) [33, 43]. The actual size, shape, and location of the defect
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can be detected utilizing C and S scan views. Utilizing two dimensional representation of a defect, it is difficult
to measure actual projected cross sectional area of an irregular shape weld defect. For simplicity in
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measurement, all defects were assumed to be rectangular in shape. The width and length of the defects were
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calculated utilizing S-scan view and C-scan view, respectively. For verification of PAUT measurement, actual
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projected cross sectional area was measured utilizing optical microscope (OM). Fig. 3 shows the cross sectional
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view of the tensile tested samples with different types of weld defects obtained with OM. Using image
processing software (Image- J), the projected cross sectional area of the defect was calculated. The small
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discrepancies between the two measurements techniques are discussed in the following paragraph.
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The cross sectional area of the defect was measured from PAUT and OM images, from which the cross
sectional area-ratio was calculated by dividing the measured cross sectional area of the defect with original
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cross sectional area of the sample. PAUT measurements were performed before tensile test and OM
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measurements were performed after the tensile test. Fig. 4 shows the relation between cross sectional area-ratio
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measured with PAUT and OM. Only a very small difference is observed in the plotted data, which shows that
PAUT can be confidently used to measure weld defects over a wide range of defect sizes as indicated by the
linear relationship between two different measurement techniques. The small variation in the results may have
occurred from measurement errors, assumption of a rectangular defect shape in PAUT measurements, and
deformation of the specimen after tensile testing. In the current study, the tensile strains were below 5% for the

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defective samples and accordingly, the deformation effect was neglected during cross sectional area
measurement of the defects using OM.
By controlling welding conditions and welding process parameters weld defects can be controlled in
automated GTA welding. However, weld defects are common in manual GTA welding of aluminum alloys.
Therefore, it is important to know the effect of weld defects on mechanical performances. In the current study
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the welded samples were classified into four different groups according to the defect location, size, and shape.
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Six samples were tensile tested from each group to obtain mechanical performances. Fig. 5 shows the average
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tensile stress-strain curve with different weld defects. As expected, defect-free samples exhibited highest tensile
strength and toughness values compared with the defective welded samples. The ultimate strength for the six
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defect-free tensile specimens ranged from 170 MPa to 182 MPa, averaging 177 MPa. The average toughness
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value was 14.1 MJ/m3. All defect-free tensile tested samples fractured near the heat-affected-zone (HAZ). The
weld-defect type is found to be directly related with the tensile strength and specimen toughness. Specimens
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with voids had an average tensile strength of 162 MPa while their toughness was 8.3 MJ/m3. These tensile
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strength and toughness values were lower by 9% and 41% compared to defect-free specimens, respectively.
Lack of fusion (LOF) has resulted in an 18% reduction in tensile strength and 65% reduction in toughness
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compared with defect-free welded samples. The corresponding reduction was 32% and 81% for lack of
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penetration (LOP). Table 2 shows the average tensile properties along with cross sectional area reduction ratio
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of four different groups with their standard deviations. In a defective sample crack generally initiates from the
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defect sites. Defects on the surface (here, LOP) are more inclined to crack initiation sites as compared to
internal defects [44]. As a results, sample with LOP defects provided lowest tensile properties. Internal defects
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(here, LOF and voids) are not so detrimental until the defect size turned into a critical value of the crack length.
Sample with LOF has larger internal defect as compared to sample with internal voids and accordingly,
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specimen with LOF defect exhibited lower tensile properties as compared to sample with internal voids.
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Weld defects have direct influence on the reduction in tensile strength as well as in the tensile strain. To
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study the effect of welding defect size on the tensile strength, UTS vs. measured defect cross sectional area ratio
was plotted (see Fig. 6). The tensile strength decreases linearly with the increase of area reduction ratio [6].
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Fig. 7 shows the relation between toughness and measured cross sectional area ratio and it is found that, for
small voids (defect area-ratio less than 0.05) in the fusion zone, the ultimate tensile strength decreased about
5%, whereas toughness decreased about 20%. A sudden drop in the tensile toughness was observed near area-
ratio around 0.05. About 16% and 60% reduction were observed in tensile strength and toughness, respectively,
when defect area-ratio reaches about 0.05. The sudden drop in toughness might be related to rapid decrease in

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tensile strain with defect size. If the defect size is higher than a critical value, crack propagation resistivity
decreased, which results in sudden failure. After the threshold value, toughness value decreases linearly with the
increasing projected defect area. Fig. 6 and 7 show good agreement with PAUT and OM data.
In order to understand the fracture pattern, tensile tested specimens were examined under the scanning
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electron microscope (SEM). Micrographs were taken at weld zone and heat-affected-zone (HAZ) of as-welded
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(AW) defect-free and base metal specimens (Fig. 8). Defect-free as-welded specimens generally failed near
weld zone. The fracture surface of welded specimen shows ductile features, in addition to that, the size and the
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spacing between the grains produced at welded area were large, which is indicative of the ductility of the weld
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area. Based on Fig. 8 it can be observed that the presence of dimples dominated the fracture surfaces, reflecting
that most of the failure was the result of the ductile fracture; and this interpretation was in good agreement with
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the work reported by several earlier researchers [31, 45, 46]. In the case of un-welded specimen, the grain size
was small and the distance between different grains was also considerably small. The welded specimens with
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no-defects failed at the HAZ. It is obvious that at this zone, large grain particles are visible. Furthermore, the
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microstructure is inhomogeneous and coarse due to the welding process; therefore, a weak area was formed at
the HAZ, causing the specimen to fail [47].
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SEM fractographic analyses were also performed to understand the fracture behavior of the defective
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samples (Fig. 9). In defective samples, the crack initiates from the defective region (e.g., LOP, LOF, and void)
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and then propagates through the weld metal. Brittle fracture surface was observed in the defective areas
followed by ductile failure behavior in the non-defective regions. The LOP is a surface defect and results in
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higher stress concentration near the defective area. As a consequence, lowest tensile strength and strain were
experienced. Voids and LOF are sub-surface defects and are also a source of stress concentration but their
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effects are considerably lower than surface defects. But within the sub-surface defects, tensile samples with
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LOF indicated higher area reductions and lower strength, compared to tensile samples with voids.
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Effects of post-weld heat treatment (PWHT)

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Complex heating cycles during welding process results in dissolution of alloying elements, intrinsic
microstructural changes, and post-weld residual stresses development in welded structures. Therefore,
precipitate strengthened aluminum alloys show lower mechanical properties in the weld zone [48, 49]. In the
current investigation, about 47% reductions in ultimate tensile strength observed in as-welded (AW) specimens
as compared to base metal (Fig. 10 and Table 3). Post-weld heat treatment (PWHT) is a common practice to

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refine grain-coarsened microstructures [31], remove or redistribute post-weld residual stresses [50], and
improve mechanical properties of heat-treatable welded aluminum alloys [39]. The effects of PWHT on tensile
properties are illustrated in Fig. 10 and Table 3. Initially only age-hardening (AH) was performed on defect-free
welded specimens. Artificial age hardening helps in supersaturated alloying element decomposes into
precipitation hardening phase [31, 51]. But it cannot help in the microstructure rearrangements or residual stress
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removal. Therefore, only AH does not necessarily have too much beneficial effect on tensile properties
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improvement. About 7% improvements in ultimate tensile strength (UTS) and 16% improvement in yield
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strength (YS) observed in the age-hardened (AH-10h) specimens. Then solution-treatment (ST) followed by
quenching was applied on defect-free welded specimens to improve tensile properties. Closely packed atoms of
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the solute uniformly distribute into the solution due to solution-treatment (ST). After quenching, the solute
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atoms then form Guinier-Preston (GP) zones which are connected with the solvent matrix [52]. Conversely,
solution treatment followed by quenching induces compressive stress fields near the weld joints and
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subsequently reduces tensile residual stresses. In a previous study [53] residual stresses are measured utilizing
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non-destructive ultrasonic testing and hole drilling techniques. It was showed that the PWHT results in about
45% removal of post-weld tensile residual stresses in GTA welded AA-6061-T651aluminum alloy. Only
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solution-treated (ST) specimens showed about 70% joint efficiency (JE) based on UTS and 51% JE based on
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YS. Artificial age-hardening (AH) was performed on ST -specimens to obtain optimum tensile strength. Age-
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hardening after the solution-treatment (STAH) helps in the precipitation hardening of the aluminum alloy. The
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alloying elements slowly precipitate into the grain boundary and impede the dislocations movement; thus higher
strength can be obtained. However, longer aging time results in over precipitation as well as precipitation-free
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zone [54]. Therefore, optimum aging period is important to achieve better mechanical properties. For GTA-
welded AA-6061-T651 peak aging time was 5 hours at 180°C. STAH-5h treated specimens showed about 85%
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JE based on UTS and 71% JE based on YS. However toughness decreased about 29%. Filler metal ER- 4043
containing lower alloying element behaves differently than base metal AA-6061-T651 aluminum alloy with
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PWHT. Due to PWHT base and filler metal interface became strengthened due to grain refinement and
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precipitation hardening. Therefore failure occurred near fusion zone where weaker filler metal present. Aging
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time of 18 hours resulted lowest toughness (6.7% JE based on toughness values).
For better understanding of the effect of PWHT, hardness values were measured in welded specimens
(Figure 11). As expected, for the as-welded (AW) specimens the major softened region is the weld -center area
and the adjacent HAZ area [21-23]. The lowest hardness values for AW- specimens are in the fusion zone and
HAZ areas, are about 55 HR15T and 53 HR15T, respectively. Fig. 11 also reveals that heat treatment processes

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are beneficial as the hardness values for all of the three zones are higher than the corresponding values of AW-
specimens. Higher hardness values also related higher tensile strength of PWHT specimens. Hardness values
increased due to precipitation hardening and grain refinement during PWHT. However, only age-hardening
(AH) does not have the full effect on grain refinement. As a result the weakest zone of AW and AH-10h
specimens are in the HAZ areas (about 10 mm away from weld-center). It was observed that solution treatment
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followed by artificial age-hardening (STAH) helps in grain refinement (Fig. 12) as well as precipitation
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hardening in welded specimens. This is also verified in other studies [26, 36, 37, 53]. For this reason, higher
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hardness values were observed near HAZ of STAH specimens. But, the welded zone showed the lowest
hardness values due to lower alloying elements present in the filler metal. Lowest hardness values in the welded
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zone are associated with lower tensile properties of ER4043 filler metal (See Table 1). STAH-5h specimens
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observed to have lowest hardness values about 68 HR15T at the center of weld joint, which is about 25% higher
than AW specimens.
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The fracture surfaces of the heat-treated specimens were characterized using SEM to understand the failure
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patterns. The SEM images were taken at the center of the failure surface (Fig. 13). The micrographs indicate
that all the surfaces invariably consist of dimples, which is a typical indication that most of the failure occurred
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due to ductile fracture. During tensile testing of ductile materials voids are formed prior to necking. If the
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necking in the specimens is formed earlier, the void formation would be much more prominent; and as result,
coarse and elongated dimples can be seen. Defect-free as- welded and only age-hardened (AH) specimens failed
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at the HAZ due to the presence of inhomogeneous and grain-coarsened structure. This is also related to lowest
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hardness values at HAZ of AW and AH specimens. On the other hand, STAH specimens failed near weld zone
for the lower hardness as well as lower tensile properties of the filler metal (Table 1). STAH-5h sample contains
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a large number of fine dimples and larger sized voids. Fine grain results in higher tensile strength and the larger
voids might be related to isolated second phases on the dendrite boundaries between filler metal and base metal.
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Over-aging results in more voids and consequences lower tensile strength and lower toughness values. The
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shiny and thick grain boundaries are observed in STAH-18h sample. The thick grain boundary associated with
the formation of precipitate-free zone [54] and generally responsible for brittle failure.
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CONCLUSIONS
In this current experimental analysis the effect of weld defects and post-weld heat treatments (PWHT) are
investigated on Gas Tungsten Arc (GTA) welded aluminum alloy AA-6061-T651. A brief summary from this
study are as follows:
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Non-destructive phased array ultrasonic testing (PAUT) can be successfully applied to locate welding
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defects. The PAUT results were compared with destructively measured values for validation. The results
revealed that PAUT can be confidently used for estimating weld-defect size and location.
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 Weld defects have direct effect on the tensile strength and toughness values of GTA-welded structures.
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The tensile strength decreased linearly with the increase of weld defect size. However, tensile toughness
behaves non-linearly with defect size. Small voids (area-ratio <0.05) does not have significant effect on
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toughness values. Once the defective area-ratio exceeds a certain critical threshold value (≥ 0.05)
toughness value decline sharply. After the threshold value of the defect area-ratio achieved, toughness
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value decreases linearly with increasing projected defect-area.
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 Solution-treatment followed by artificial age-hardening generally needed to enhance tensile properties of
welded aluminum alloys. The experimental results confirmed that the mechanical properties of the AA-
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6061-T651 joints with PWHT were significantly improved in comparison to as-welded specimens.
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However, exposing the material to a temperature for longer time than optimally required aging time can
create larger precipitation-free zone, impose brittleness, and consequently lower the tensile properties.
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And therefore, it is necessary to obtain optimum aging temperature and time for achieving better
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strength.
 In some industrial applications it may be difficult and not cost-effective to apply solution treatment
followed by required age hardening (STAH). In that case, only age hardening (AH) can be applied to
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improve mechanical performances up to a certain extent; but for small and critical-application
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components STAH can be applied to obtain best mechanical performances.

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ACKNOWLEDGEMENTS
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Authors gratefully acknowledge the financial support received from the U.S. Nuclear Regulatory
Commission (U.S. Nuclear Regulatory Grant Account # NRC-HQ-11-G-38-0052). Authors also appreciate
assistances received from Mr. Paul Rodriguez during welding and sample preparations.
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REFERENCES
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Figure Caption List
Fig. 1. Welding configurations and tensile specimens (all dimensions are in millimeter)
Fig. 2. The C and S- scan views of tensile test samples obtained with PAUT: a) no-defect, b) voids, c) LOF
(Lack of Fusion), and d) LOP (Lack of weld Penetration)
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Fig. 3. Cross sectional view of tensile tested specimens with different weld defects obtained with Optical
Microscope (OM)
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Fig. 4. Plot shows the relationship between the defect sizes measured with OM and PAUT
Fig. 5. Tensile test curves of GTA- welded AA-6061-T651 aluminum alloy with different welding defect
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Fig. 6. Tensile strength vs. defect cross sectional area ratio measured with PAUT and OM
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Fig. 7. Toughness vs. Area reduction ratio measured with PAUT and OM
Fig. 8. SEM Fractographs of (a) base metal of un-welded specimen, (b) weld metal of as-welded (AW)
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Fig. 9. SEM Fractographs of tensile tested welded specimens with different types of weld defects
Fig. 10. Variations of tensile strength and toughness due to PWHT
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Fig. 11. Effect of PWHT on hardness profile

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Fig. 12. Effect of PWHT on fusion zone microstructure. Finer microstructures are observed in (b) heat-treated
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(STAH-5h) specimen as compared to (a) as-welded (AW) specimen.

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Fig. 13. SEM Fractographs of PWHT samples: (a) only AH, (b) STAH-5h, (c) STAH-18h
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Table Caption List
Table 1. Chemical composition and tensile strength of base metal and filler rod
Table 2. Average tensile test results with different weld defects
Table 3. Effects of PWHT on Joint Efficiency (JE) of GTA- welded AA-6061-T651 aluminum alloy.
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Fig. 1.
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Fig. 2.
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Fig. 3.
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Fig. 4.
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Fig. 5.
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Fig. 6.
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Fig. 7.
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Fig. 8.
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Fig. 9.
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Fig. 10.
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Fig. 11.
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Fig. 12.
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Fig. 13.
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Table 1. Chemical composition and tensile strength of base metal and filler rod [41]
Cr Cu Fe Mg Mn Si Ti Zn Al YS, UTS,
MPa MPa
AA-6061- 0.04-0.35 0.15-0.40 <0.70 0.80-1.2 <0.15 0.40-0.80 <0.15 <0.25 95.8-98.6 334 305
T651
ER-4043 -- <0.30 <0.80 <0.05 <0.05 4.50-4.60 <0.20 <0.10 92.3-95.5 124 186
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Table 2. Average tensile test results with different weld defects

UTS (MPa) Strain Toughness Area-ratio Area-ratio
(mm/mm) (MJ/m^3) (OM) (PAUT)
LOP 119.1 ± 2.9 0.01 ± 0.005 2.6 ± 0.26 0.15 ± 0.02 0.14 ± 0.02
LOF 146.5 ± 8.8 0.02 ± 0.007 4.8 ± 0.61 0.08 ± 0.02 0.08 ± 0.02
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Voids 162.6 ± 10.1 0.04 ± 0.013 8.3 ± 2.12 0.05 ± 0.03 0.05 ± 0.02
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No-Defect 176.8 ± 5.9 0.06 ± 0.012 14.1 ± 1.35 0.0 ± 0.0 0.0 ± 0.0
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Table 3. Effects of PWHT on Joint Efficiency (JE) of GTA- welded AA-6061-T651 aluminum alloy.
Heat- JE (%), JE (%), Toughness, JE (%),
UTS, MPa YS, MPa
treatments UTS YS MJ/mm3 Toughness
Base 334.08 100.00 305.57 100.00 31.07 100.02
AW 176.87 52.94 103.50 33.87 16.91 54.41
AH 197.27 59.05 156.26 51.14 13.04 41.95
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ST 234.53 70.20 156.18 51.11 18.04 58.06
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STAH-3h 273.32 81.81 232.16 75.98 7.38 23.75
STAH-5h 283.83 84.96 217.96 71.33 8.00 25.74
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STAH-7h 248.01 74.24 198.71 65.03 4.58 14.73
STAH-18h 227.23 68.02 205.44 67.23 2.09 6.73
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Dewan 2015

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Journal of Manufacturing Science and Engineering.

Received December 10, 2014;

Louisiana State University and A&M College

Baton Rouge, LA 70803

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dogbone tensile samples.

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followed by Age- Hardening specimens are named as STAH.

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RESULTS AND DISCUSSIONS

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Effects of post-weld heat treatment (PWHT)

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time of 18 hours resulted lowest toughness (6.7% JE based on toughness values).

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components STAH can be applied to obtain best mechanical performances.

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Properties of 5083 Aluminum Alloy Welds, Defense Technical Information Center.

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Journal of Minerals, Metallurgy, and Materials, 20(3), pp. 259-265.

Society of China, 24(5), pp. 1307-1316.

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54, pp. 6-13.

laser/GMA welds," Materials Science and Engineering: A, 459(1–2), pp. 94-100.

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Figure Caption List

Fig. 11. Effect of PWHT on hardness profile

(STAH-5h) specimen as compared to (a) as-welded (AW) specimen.

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Table Caption List

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Table 2. Average tensile test results with different weld defects

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