CN114346385A - Aluminum-based welding electrode - Google Patents
Aluminum-based welding electrode Download PDFInfo
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- CN114346385A CN114346385A CN202111195066.7A CN202111195066A CN114346385A CN 114346385 A CN114346385 A CN 114346385A CN 202111195066 A CN202111195066 A CN 202111195066A CN 114346385 A CN114346385 A CN 114346385A
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Abstract
The disclosed technology relates generally to welding, and more particularly to aluminum-based consumable electrodes and welding methods using the same. In one aspect, a consumable welding electrode includes a base metal composition comprising at least 70% by weight aluminum and a mobility enhancing metal capable of forming a binary eutectic with aluminum, wherein the binary eutectic undergoes a binary eutectic solidification at a eutectic temperature of 595-660 ℃. The fluidity enhancing metal is present in a form and hypoeutectic concentration of 0.05 to 0.5 weight percent such that a solidification temperature range of molten weld metal formed by melting the consumable welding electrode is less than 65 ℃.
Description
Cross Reference to Related Applications
The present application claims priority from U.S. non-provisional patent application No. 17/446,778 entitled "ALUMINUM-BASED WELDING ELECTRODES" filed on 9/2/2021, and U.S. non-provisional patent application No. 17/464,535 entitled "ALUMINUM-BASED WELDING ELECTRODES" filed on 9/1/2021, and U.S. provisional patent application No. 63/090,867 entitled "ALUMINUM-BASED WELDING ELECTRODES" filed on 10/13/2020, the contents of which are incorporated herein by reference in their entirety.
Background
Technical Field
The disclosed technology relates generally to welding, and more particularly to aluminum-based consumable electrodes and welding methods using the same.
Description of the Related Art
The engineering use of aluminum and its alloys continues to increase because of the various advantageous properties of this unique material. Advantageous features of aluminum and its alloys include light weight, relatively broad tunable strength characteristics, excellent corrosion resistance, thermal conductivity, reflectivity, and widely available shapes and compositions, to name a few. Because of these and other characteristics, aluminum can be an excellent choice in many applications ranging from aerospace to heat exchangers, trailer manufacturing, and more recently automotive body panels and frames. However, welding aluminum may present unique challenges, including inhibiting weld defects and improving the properties of the weld metal.
SUMMARY
In one aspect, a consumable welding electrode includes a base metal composition comprising at least 70% by weight aluminum and a mobility enhancing metal capable of forming a binary eutectic with aluminum, wherein the binary eutectic undergoes a binary eutectic solidification at a eutectic temperature of 595-660 ℃. The fluidity enhancing metal is present in a form and hypoeutectic concentration of 0.05 to 0.5 weight percent such that a solidification temperature range of molten weld metal formed by melting the consumable welding electrode is less than 65 ℃.
In another aspect, a consumable welding electrode includes a base metal composition comprising at least 70% by weight aluminum and a mobility enhancing metal capable of forming a binary eutectic with aluminum, wherein the binary eutectic undergoes a binary eutectic solidification at a eutectic temperature of 595-660 ℃. The mobility enhancing metal is present in the form of a compound selected from the group consisting of an oxide, halide, hydroxide, sulfide, sulfate, carbonate, phosphate, nitride, nitrite, nitride, carbide, boride, aluminide, telluride, or combinations thereof.
In another aspect, a consumable welding electrode includes a base metal composition comprising at least 70% by weight aluminum and a mobility enhancing metal capable of forming a binary eutectic with aluminum, wherein the binary eutectic undergoes a binary eutectic solidification at a eutectic temperature of 595-660 ℃. The fluidity enhancing metal is present in a form and a hypoeutectic concentration such that a molten weld metal formed from the consumable welding electrode has a fluidity at least 5% higher relative to a molten weld metal formed using a consumable welding electrode having the same base metal composition but without the fluidity enhancing metal under substantially the same welding conditions.
In another aspect, a consumable welding electrode includes a base metal composition comprising at least 70% aluminum by weight, and a flowability enhancing metal capable of forming a binary eutectic composition with the aluminum, wherein the binary eutectic composition undergoes binary eutectic solidification at a eutectic temperature less than 90 ℃ below the melting point of pure aluminum, wherein the flowability enhancing metal is present in a form and in an amount such that a weld metal formed from the consumable welding electrode has one or more of the following relative to a weld metal formed under substantially the same welding conditions using a consumable welding electrode without the flowability enhancing metal:
the weld metal height (H) is at least 5% lower,
the weld metal width (W) is at least 5% greater,
the H/W ratio is at least 5% less,
a degree of penetration (P) of at least 5% less, and
the weld toe angle (q) is at least 5% less.
In one aspect, a consumable welding electrode includes a base metal composition comprising at least 70% by weight aluminum and a mobility enhancing metal capable of forming a binary eutectic composition with the aluminum, wherein the binary eutectic composition undergoes binary eutectic solidification at a eutectic temperature less than 90 ℃ below the melting point of pure aluminum. The fluidity enhancing metal is present in a form and in an amount such that the molten weld metal formed from the consumable welding electrode has a fluidity that is at least 5% higher relative to the fluidity of a molten weld metal formed under substantially identical welding conditions using a consumable welding electrode without the fluidity enhancing metal.
In another aspect, a consumable welding electrode includes a base metal composition comprising at least 70% by weight aluminum and a fluidity enhancing metal selected from the group consisting of: nickel (Ni), gold (Au), calcium (Ca), strontium (Sr), scandium (Sc), yttrium (Y), terbium (Tb), europium (Eu), cerium (Ce), praseodymium (Pr), ytterbium (Yb), holmium (Ho), erbium (Er), lanthanum (La), dysprosium (Dy), samarium (Sm), lutetium (Lu), thulium (Tm), neodymium (Nd), gadolinium (Gd), lithium (Li), iron (Fe), cadmium (Cd), or a combination thereof. The flowability enhancing metal is present in an amount greater than 0.05% by weight and less than or equal to the binary eutectic composition based on the combined weight of aluminum and the flowability enhancing metal.
In another aspect, a consumable welding electrode includes a base metal composition comprising at least 70% by weight aluminum and a fluidity enhancing metal selected from the group consisting of: nickel (Ni), gold (Au), calcium (Ca), strontium (Sr), scandium (Sc), yttrium (Y), terbium (Tb), europium (Eu), cerium (Ce), praseodymium (Pr), ytterbium (Yb), holmium (Ho), erbium (Er), lanthanum (La), dysprosium (Dy), samarium (Sm), lutetium (Lu), thulium (Tm), neodymium (Nd), gadolinium (Gd), lithium (Li), iron (Fe), cadmium (Cd), or a combination thereof. The fluidity enhancing metal is present in a form and in an amount such that the molten weld metal formed from the consumable welding electrode has a fluidity that is at least 5% higher relative to the fluidity of a molten weld metal formed under substantially identical welding conditions using a consumable welding electrode without the fluidity enhancing metal.
In another aspect, a consumable welding electrode includes a base metal composition comprising at least 70% by weight aluminum and a fluidity enhancing metal selected from the group consisting of: nickel (Ni), gold (Au), calcium (Ca), strontium (Sr), scandium (Sc), yttrium (Y), terbium (Tb), europium (Eu), cerium (Ce), praseodymium (Pr), ytterbium (Yb), holmium (Ho), erbium (Er), lanthanum (La), dysprosium (Dy), samarium (Sm), lutetium (Lu), thulium (Tm), neodymium (Nd), gadolinium (Gd), lithium (Li), iron (Fe), cadmium (Cd), or combinations thereof, wherein the mobility enhancing metal is present in a form and in an amount such that a weld metal formed from the consumable weld electrode has one or more of the following relative to a weld metal formed under substantially identical welding conditions using a consumable weld electrode without the mobility enhancing metal:
the weld metal height (H) is at least 5% lower,
the weld metal width (W) is at least 5% greater,
the H/W ratio is at least 5% less,
a degree of penetration (P) of at least 5% less, and
the weld toe angle (q) is at least 5% less.
In yet another aspect, a method of welding aluminum workpieces includes providing a consumable welding electrode according to any including an aluminum-based base metal composition and a fluidity-enhancing metal selected from the group consisting of: nickel (Ni), gold (Au), calcium (Ca), strontium (Sr), scandium (Sc), yttrium (Y), terbium (Tb), europium (Eu), cerium (Ce), praseodymium (Pr), ytterbium (Yb), holmium (Ho), erbium (Er), lanthanum (La), dysprosium (Dy), samarium (Sm), lutetium (Lu), thulium (Tm), neodymium (Nd), gadolinium (Gd), lithium (Li), iron (Fe), cadmium (Cd), or a combination thereof; and generating an arc to form weld metal using the consumable welding electrode at a weld travel speed of 10-50 inches per minute.
Drawings
FIG. 1 is a schematic view of a metallic arc welding process.
Fig. 2 is a schematic cross-sectional view of a weld.
FIG. 3A is an idealized binary phase diagram of an alloy illustrating the solidification temperature range of an alloy with a binary eutectic.
FIG. 3B is a binary phase diagram of the Al-Ce alloy system.
FIG. 4A is a schematic illustration of a solid welding wire having a fluidity-enhancing metal alloyed therein to enhance the fluidity of the molten weld metal, in accordance with an embodiment.
FIG. 4B is a schematic illustration of a solid welding wire having a fluidity enhancing metal compound mixed therein to enhance the fluidity of molten weld metal, in accordance with an embodiment.
FIG. 4C is a schematic illustration of a coated solid welding wire configured to enhance molten weld metal fluidity, according to an embodiment.
FIG. 4D is a schematic illustration of a cored welding wire configured to enhance molten weld metal fluidity, according to an embodiment.
Fig. 5 is a flow chart illustrating a method of enhancing the fluidity of molten weld metal during aluminum welding according to an embodiment.
FIG. 6 illustrates a Gas Metal Arc Welding (GMAW) system adapted to weld aluminum using a wire configured to enhance fluidity of molten weld metal, in accordance with an embodiment.
Detailed Description
The weight of aluminum is about one third of that of steel. The weight of one cubic inch of aluminum is 0.098lbs./in3And the weight of one cubic inch of steel is 0.283lbs./in3. Aluminum has a wide range of strength characteristics, ranging from the tensile strength of pure aluminum at 13,000psi to the tensile strength of the strongest heat-treated aluminum alloy at 90,000 psi. Aluminum provides excellent corrosion resistance in many environments. The thin refractory oxide formed on the aluminum surface provides a protective barrier. Aluminum has five times the thermal conductivity of steel. Aluminum reflects radiant heat and surface finishing of aluminum often takes advantage of this feature. Because of these and other advantageous properties of aluminum, the engineering applications for aluminum are increasing in number and complexity. Accordingly, the challenges of welding aluminum are increasing, including suppressing weld defects and improving the properties of the weld metal. In general, aluminum is believed to have relatively lower weldability than steel for a variety of reasons, including higher affinity of aluminum for atmospheric gases, higher coefficient of thermal expansion, higher thermal and electrical conductivity, lower rigidity, and a higher cure temperature range. These characteristics of aluminum alloys may generally make the weld aluminum more susceptible to forming defects in the weld metal.
Many aluminum-based welding electrodes exhibit poor molten weld metal fluidity. Among the various causes of reduced weldability of Al, the lower flow properties of molten weld metals formed from some aluminum-based welding electrodes cause a specific type of defect in the weld metal. For example, less molten weld metal fluidity may result in undercutting at higher travel speeds, poor wetting at the weld toe, higher porosity, and lower penetration. Less molten weld metal fluidity may also result in higher porosity in the weld metal due to interdendritic porosity formation. In addition, less molten weld metal fluidity may result in a higher weld bead, which in turn may increase the likelihood of stress concentrations at the weld toe and lead to failure of the fatigue mode. In addition to being prone to these weld metal defects, because lower molten weld metal fluidity may limit controllability of the weld pool, which may in turn limit welding to smaller travel speeds, which reduces productivity.
Furthermore, while some aluminum-based welding electrodes provide higher melt weld fluidity than others (e.g., 4XXX alloys), they pose different challenges. For example, some elements are known to provide higher melt solder fluidity, such as silicon. However, the weld shear strength of the weld metal formed from the Al-based welding electrode containing Si may be compromised. Thus, electrodes based on 4XXX alloys may not be suitable for welding workpieces formed from 5XXX alloys for some applications because of brittle phases such as Mg2The Si phase may reduce the ductility of the weld.
Without limitation, the disclosed technology addresses these and other aspects of aluminum-based welding electrodes. In particular, the disclosed welding electrodes according to various embodiments disclosed herein include alloying elements that can increase molten weld metal fluidity without substantially compromising some desirable characteristics, such as shear strength.
Arc welding using aluminum-based welding wire
FIG. 1 is a schematic illustration of a configuration of an Al-based wire or electrode in a metallic arc welding process, according to an embodiment. According to an embodiment, the Al-based welding wire 6 may be configured as a lower fluidity molten weld metal. In the illustrated metallic arc welding, such as gas-metal arc welding (GMAW), an arc is generated between a consumable Al-based wire 6 electrically connected to one electrode 4 (e.g., an anode (+)) and a workpiece 2 serving as another electrode (e.g., a cathode (-)). Thereafter, a plasma 8 is maintained, which contains neutral and ionized gas molecules, as well as neutral and charged clusters or droplets of the material of the Al-based welding wire 6 that have been vaporized by the arc. During welding, the consumable welding wire 6 is advanced towards the workpiece 2 and the resulting molten weld metal droplets formed from the Al-based welding wire 6 are deposited onto the workpiece, thereby forming a weld metal or bead.
The Al-based welding wire 6 may be used for different arc welding processes, including gas-metal arc welding processes that may employ a solid electrode wire (GMAW) or a metal-cored wire (GMAW-C). The Al-based wire 6 may also be used in a flux-cored arc welding process (FCAW), which may be gas shielded flux-cored arc welding (FCAW-G) or self-shielded flux-cored arc welding (FCAW-S). The Al-based welding wire 6 may also be used in particular for Shielded Metal Arc Welding (SMAW) processes and Submerged Arc Welding (SAW) processes.
Aluminum-based welding wire with enhanced fluidity for molten welding metal
To address the above and other challenges of aluminum welding, a welding wire according to embodiments is configured to substantially increase the fluidity of molten weld metal. To enhance the fluidity of the molten weld metal, the welding wire 6 (fig. 1) according to an embodiment includes an Al-based base metal composition including at least 70% by weight of aluminum and a fluidity-enhancing metal. The base metal composition may additionally include any other elements that may be used to provide the desired properties of the final weld metal, including elements that may overlap with elements present in the workpiece. As discussed more below, the inventors have discovered that effective fluidity enhancing metals include metals that are capable of forming a binary eutectic with aluminum, wherein the binary eutectic undergoes binary eutectic solidification at a eutectic temperature less than 90 ℃ below the melting point of pure aluminum. The fluidity enhancing metal is present in a form and in an amount such that a molten weld metal formed from the consumable welding electrode has a fluidity that is at least 5% higher relative to a molten weld metal formed using a base metal composition without the fluidity enhancing metal. Increasing the fluidity of the molten weld metal increases the controllability of the weld pool, which in turn enables welding at faster travel speeds, thereby increasing productivity. The enhanced flow may also result in improved performance of the resulting weld metal, for example, by reducing the various undesirable weld properties described above, including undercut, poor wetting at the weld toe, higher porosity, lower permeability, and higher weld bead.
Fluidity of molten weld metal&Welding metal shapes
As described herein and in the welding art, the term fluidity, as it relates to molten metal, refers to, without limitation, metallurgical fluidity, which is a measure of the distance the molten metal can flow in a mold of constant cross-sectional area before it solidifies. It will be understood that this definition is different from the one proposed in physics, which describes fluidity as the inverse of viscosity, a property that is related to the base temperature of a liquid.
As described herein, the term fluidity shall include metallurgical and physical definitions, unless the description of the molten weld metal disclosed herein is incompatible under either definition. However, if the description of molten weld metal as disclosed herein is incompatible under either definition, the term fluidity shall mean one of the metallurgical and physical definitions that do not render the description incompatible.
Many methods can be used to measure the fluidity of molten metal. It is common for many measurement techniques to flow molten metal into narrow channels. Flowability is reported as a measure of the length or volume of the mold that the metal stream fills before it solidifies. The flowability test can be carried out in different ways. The spiral die test and the vacuum flow test are among the most popular flow tests. The former test measures the length of molten metal flow within a spiral die. The latter test measures the length of metal flow in a narrow channel when siphoned from a crucible using a vacuum pump. These and other methods are disclosed in m.di Sabatino, "Fluidity of Aluminum fountain Alloys (Fluidity of Aluminum casting Alloys)," doctor paper filed to norwegian university (2005) and "On Fluidity of Aluminum Alloys (Fluidity for Aluminum Alloys)," La metalluria Italiana 100(3):17-22(2008), the contents of each of which are incorporated by reference in their entirety.
As described herein, unless the description of the fluidity of the molten weld metal as disclosed herein is incompatible when measured using any of the above tests, the fluidity shall refer to the fluidity measured using any and all of the above tests. However, if the fluidity of the molten weld metal as disclosed herein is not compatible under any of the above-mentioned test regimes, then said fluidity shall mean the fluidity measured using any of the above-mentioned tests which give results compatible with the present specification.
The fluidity of weld metal is affected by a number of factors, including thermodynamic parameters such as the chemical composition, solidification range and heat of fusion of the molten weld metal, and physical parameters such as viscosity and surface tension, to name a few. In particular, the kinetics of solidification of the weld play an important role in determining the fluidity of the weld. The solidification of the weld is in turn largely controlled by the weld composition and thermodynamic results derived therefrom, as further described below.
The weld flow properties directly affect the shape of the resulting weld metal, as schematically illustrated in fig. 2. FIG. 2 is a schematic cross-sectional view of a metal weld 26 formed on a workpiece or substrate 22, and a region or penetration zone 24 having deep thermal effects within the workpiece 22. As described herein, the weld metal 26 can be characterized by a weld height (H), a weld width (W), a penetration depth (P), and a toe angle (θ). H and P are measured in a vertical direction from the plane of the major surface of workpiece 22. W is measured in a lateral direction along the plane of the major surface of workpiece 22. Q is measured between the plane of the major surface of the workpiece 22 and the tangent at the bottom of the weld metal 26. As discussed above, for many applications, higher fluidity of the molten weld metal may be desirable, which in turn results in again lower H, greater W, smaller H/L ratio, greater P, and smaller θ.
It will be appreciated that by varying several process parameters, different weld profiles can be obtained for a given composition. For example, increasing Wire Feed Speed (WFS) and contact-to-work distance (CTWD) at a particular arc voltage may result in H, W or an increase in H/W. At constant WFS, H may increase and/or W may decrease as the arc voltage decreases. In addition to process parameters, because the shape of the molten metal depends on many extrinsic factors, such as the composition, shape, and surface condition of the workpiece, those of ordinary skill in the art will appreciate that the most meaningful measure of the improvement in the fluidity of the molten weld metal formed by a welding electrode having a fluidity enhancing metal present therein can be made when comparing the weld metal so formed to a weld metal formed using a consumable welding electrode having the same base metal composition but without the fluidity enhancing metal under substantially the same welding conditions.
Composition and thermodynamic properties of fluidity-enhanced weld metal
For pure metals or eutectic alloys, solidification occurs at a single temperature. In the case of alloys at compositions other than eutectic temperatures, solidification of the liquid mixture can occur over a range of temperatures. In this temperature range, deposition of one or more phases may occur. The inventors have found that deposition can result in the formation of a "mushy" zone comprising a slurry mixture of liquid and deposit between the solidified weld metal and the weld line. Without being bound by any theory, the deposit formed during solidification may act as a nucleation site for new particles, which may limit the fluidity of the molten weld metal. The inventors have found that the flow properties of molten weld metal are greatly enhanced by the addition of certain flow enhancing metals as alloying elements, which have a smaller range of temperatures in which "mushy" regions can form, as described herein.
FIG. 3A is a schematic idealized binary phase diagram of a hypothetical alloy undergoing solidification, for illustrative purposes only. It will be appreciated that although solidification of the weld metal may deviate significantly from equilibrium conditions, the equilibrium phase diagram provides a valuable understanding of the solidification process. The x and y axes represent the concentration and temperature of the alloying element or solute, respectively. It will be appreciated that although the phase diagram shown is idealized by assuming that the solidus and liquidus are straight lines, a practical alloy system may have curved solidus and liquidus lines. Composition XMaximum ofRepresents the maximum content of alloying elements or solutes for solidification of the binary alloy as a single-phase alloy. The distribution coefficient k can pass XS/XLIs defined in which X isSAnd XLIs the mole fraction of solute in the solid and liquid at equilibrium at a given temperature. The solidification process depends in a complex manner on various factors, such as temperature gradients, cooling rates and growth rates. Under equilibrium conditions, has a composition X0Is initiated at a temperature T1And lower curing with formation of a small amount of solid deposit with a composition kX. With decreasing temperature, e.g. at T2More solids are formed and provided that cooling is slow enough to allow extensive solid state diffusion, the solids and liquids having a composition XS，XLThe solidus and liquidus are followed. The relative amounts of solid and liquid at any temperature are given by the law of leverage. At T2The last drop of liquid will have a composition of X/k and the solidified metal will have a composition of X.
Referring back to fig. 2, solidification generally begins at the weld line defining the depth of the penetration zone 24, and the base metal particles serve as nucleation sites. Depending on whether the base alloy and the filler alloy of the Base Metal (BM) are the same or different, grain growth near the weld line occurs by epitaxial or non-epitaxial mechanisms, respectively. The remainder of the weld metal away from the weld line solidifies through a competing growth mechanism, which may depend on the direction of maximum heat extraction. With pure elements, the solder flux may flow relatively freely due to the lack of impurities in the solder flux. However, in alloys, solidification occurs over a range of temperatures, as schematically illustrated in fig. 3A at non-zero solute concentrations. This results in the formation of a "mushy" zone comprising a slurry mixture of liquid and deposits between the solidified weld metal and the weld line containing the mixture of liquid and solid deposits. The deposits formed during solidification can then serve as nucleation sites for new particles, which may impede the flow of the solder liquid. For example, the poor weld flow observed in weld metals formed from welding electrodes formed from Al-Mg alloys may be attributed in part to the large solidification range. The inventors have found that the formation of deposits that impede the flow of molten weld metal can be reduced by the addition of a fluidity-enhancing element, whereby the fluidity of the molten weld metal is greatly enhanced, wherein the fluidity-enhancing element has a smaller range of temperatures at which a "mushy" region can form.
Once the pure elements are alloyed with other elements, the fluidity initially decreases to some extent. The fluidity then begins to increase until the eutectic composition is reached, and then begins to drop below the eutectic composition again. An exception is Al-Si alloys, where the fluidity is increased above the eutectic composition (12.5 wt.% Si). Si has 4.5 times higher fusion heat than Al; this additional heat energy keeps the solder liquid flowing. In the case of Al — Mg alloys, the fluidity drops sharply from pure Al levels with the introduction of Mg up to 2 wt.% Mg; then, it was increased up to the eutectic composition (about 33 wt.% Mg).
Recognizing these attributes of weld metal fluidity, the inventors have discovered that adding certain fluidity-enhancing elements as part of the welding wire in an effective amount can significantly increase fluidity. According to various embodiments, a consumable welding electrode includes a base metal composition comprising at least 70% aluminum by weight and a fluidity-enhancing metal.
The base metal composition may have a similar composition to the workpieces to be welded. The base metal composition may include any composition known in the art according to the four digit system developed by the aluminum association to designate various wrought aluminum alloy types. The base metal composition may include one or more of the following, for example:
1XXX series: these are aluminum of 99% or higher purity, and are used mainly in the electrical and chemical industries. These alloys are typically used for their electrical conductivity and/or corrosion resistance. They have low susceptibility to thermal cracking.
2XXX series. Copper is the predominant alloy in this group and provides extremely high strength after appropriate heat treatment. These alloys may not give good corrosion resistance and are usually clad with pure aluminium or special alloy aluminium. These alloys are used in the aircraft industry.
3XXX series. Manganese is the main alloying element in this group, which is not heat treatable. The manganese content may be less than about 2.0%. These alloys have moderate strength and are easy to machine. These medium strength aluminum manganese alloys are relatively crack resistant.
4XXX series. Silicon is the main alloying element in this group. It may be added in sufficient quantity to significantly lower the melting point and be used for brazing alloys and welding electrodes. Most alloys in this group are not heat treatable.
5XXX series. Magnesium is the main alloying element in this group, which is a medium strength alloy. They have good welding characteristics and good corrosion resistance, but the amount of cold working should be limited. These higher strength aluminum magnesium alloys are the most common structural aluminum sheet and sheet alloys. This series has the highest strength of the non-heat treatable aluminum alloys. Due to their excellent corrosion resistance, they are used in chemical storage tanks and pressure vessels as well as structural applications, railway cars, dump trucks and bridges.
The 6XXX series. The alloys in this group contain silicon and magnesium, which makes them heat treatable. These alloys have moderate strength and good corrosion resistance. The medium strength, heat treatable series is primarily useful for automotive, duct, rail and structural extrusion applications.
7XXX series. Zinc is the main alloying element in this group. Magnesium is also included in most of these alloys. Together they form a very strong heat treatable alloy for use in aircraft frames. The alloy is mainly used in the aircraft industry. The solderability of the 7XXX series may be compromised in the higher copper grades because many of these grades are susceptible to cracking due to the wide melting range and low solidus melting point. They are widely used in bicycle frames and other extrusion applications.
The base metal composition of the welding wire according to various embodiments disclosed herein may include Mn in a weight percentage of 0.01% -0.02%, 0.02% -0.05%, 0.05% -0.10%, 0.1% -0.2%, 0.2% -0.5%, 0.5% -1.0%, 1.0% -1.5%, 1.5% -2.0%, or a value within a range defined by any of these values, based on the total weight of the welding wire; the weight percent of Si is 0.1% -0.2%, 0.2% -0.5%, 0.5% -1.0%, 1.0% -2.0%, 2.0% -5.0%, 5.0% -10%, 10% -15%, 15% -20%, or a value within a range defined by any of these values, based on the total weight of the welding wire; the weight percent of Fe is 0.02% -0.05%, 0.05% -0.10%, 0.1% -0.2%, 0.2% -0.5%, 0.5% -1.0%, or a value within a range defined by any of these values, based on the total weight of the welding wire; the weight percent of Mg is 0.1% -0.2%, 0.2% -0.5%, 0.5% -1.0%, 1.0% -2.0%, 2.0% -5.0%, 5.0% -10%, or a value within a range defined by any of these values, based on the total weight of the welding wire; the weight percent of Cr is 0.01% -0.02%, 0.02% -0.05%, 0.05% -0.10%, 0.1% -0.2%, 0.2% -0.5%, 0.5% -1.0%, or a value within a range defined by any of these values, based on the total weight of the welding wire; the weight percent of Cu is 0.01% -0.02%, 0.02% -0.05%, 0.05% -0.10%, 0.1% -0.2%, 0.2% -0.5%, 0.5% -1.0%, 1.0% -2.0%, 2.0% -5.0%, 5.0% -10%, or a value within a range defined by any of these values, based on the total weight of the welding wire; the weight percent of Ti is 0.02% -0.05%, 0.05% -0.10%, 0.1% -0.2%, 0.2% -0.5%, 0.5% -1.0%, or a value within a range defined by any of these values, based on the total weight of the welding wire; the weight percent of Zn is 0.05% -0.10%, 0.1% -0.2%, 0.2% -0.5%, 0.5% -1.0%, or a value within a range defined by any of these values, based on the total weight of the welding wire; and, the weight percent of Al is 70-75%, 75-80%, 80-85%, 85-90%, 90-95%, 95-99.9%, based on the total weight of the welding wire, or a value within a range defined by any of these values, which may be the balance of the welding wire or the base metal composition.
According to various embodiments, the consumable welding electrode includes a fluidity-enhancing metal present in a form and amount such that a molten weld metal formed from the consumable welding electrode has a fluidity that is at least 5%, 10%, 20%, 50%, 100%, 200%, 500%, 1000% higher, or a value in a range defined by any of these values, relative to a molten weld metal formed under substantially identical welding conditions using a consumable welding electrode having the same composition, except for the fluidity-enhancing metal.
As noted above, post-deposition characterization of the solidified weld metal can also provide an indication of the fluidity of the molten weld metal. Referring back to fig. 2, weld metal fluidity can be inferred based on weld metal form factors such as height, width, height/width ratio, and/or weld toe angle. According to various embodiments, the fluidity-enhancing metal is present in a form and in an amount such that the molten weld metal formed by the consumable welding electrode has one or more of the following characteristics relative to a weld metal formed under substantially identical welding conditions using a consumable welding electrode having the same composition except for the fluidity-enhancing metal: the weld metal height (H) is at least 5%, 50%, 100%, 150%, 200%, 250%, 300% lower or a value within a range defined by any of these values; the weld metal width (W) is at least 5%, 20%, 40%, 60%, 80%, 100% higher or a value within a range defined by any of these values; a H/W ratio that is at least 5%, 50%, 100%, 150%, 200%, 250%, 300% lower or a value within a range defined by any of these values; the degree of permeability (P) is at least 5%, 20%, 40%, 60%, 80%, 100% less or a value within a range defined by any of these values; and the weld toe angle (θ) is less than at least 5%, 20%, 40%, 60%, 80%, 100%, or a value within a range defined by any of these values.
As discussed above, the inventors have discovered that the property of an effective flowability-enhancing element is the ability to form a binary eutectic composition with aluminum in a lower temperature range, wherein a "mushy" zone is formed within the temperature range, as described above. The physical parameter indicative of this temperature range is the curing temperature range. Thus, the inventors have found that a desirable physical property of an effective flowability-enhancing element is a narrow range of curing temperatures within the relevant compositional range. The curing temperature range may be defined as being inThe temperature range between the liquidus and solidus. Referring back to FIG. 3, composition X0Has a curing temperature range of T3-T1. The inventors have further recognized that alloy systems having a narrower solidification temperature range according to embodiments form binary eutectic compositions that undergo binary eutectic solidification at a eutectic temperature that is relatively closely adjacent to the melting point of pure aluminum.
Referring back to FIG. 3A, for an idealized binary alloy system, it will be appreciated that the maximum value of the solidification temperature range does not exceed the melting point of the pure metal and the eutectic temperature TEThe difference between them. Thus, the eutectic temperature may be the selection criterion for the mobility enhancing metal. According to various embodiments, the fluidity enhancing metal forms a binary eutectic composition at a temperature that is less than 90 ℃, 80 ℃, 70 ℃, 60 ℃, 50 ℃, 40 ℃, 30 ℃, 20 ℃, 10 ℃, or less than a value within a range defined by any of these values below the melting point of pure aluminum. For the condition that the melting point of aluminum is 660 ℃, the binary eutectic composition melts at a melting point that is less than 570 ℃, 580 ℃, 590 ℃, 600 ℃, 610 ℃, 620 ℃, 630 ℃, 640 ℃, 650 ℃, 660 ℃, or a value that is less than within a range defined by any of these values. For example, a mobility enhancing metal capable of forming a binary eutectic with aluminum according to embodiments undergoes a binary eutectic solidification at a eutectic temperature of 595-660 ℃. For illustrative purposes, one example alloy system having these properties is the Al-Ce alloy system, the binary phase diagram of which is shown in FIG. 3B. As shown, the eutectic temperature of 621 ℃ is in the range of 595-660 ℃.
Table 1 below shows the estimated maximum cure temperature ranges for some example flowability-enhancing elements according to the examples. Table 2 below shows the eutectic temperature and eutectic composition and composition range for some example fluidity enhancing metals in which the flow properties of the molten weld metal are enhanced.
TABLE 1
TABLE 2
According to one embodiment, the consumable welding electrode comprises a base metal composition comprising at least 70% by weight of aluminum and a mobility enhancing metal capable of forming a binary eutectic with aluminum, wherein the binary eutectic undergoes a binary eutectic solidification at a eutectic temperature of 595-660 ℃. The fluidity enhancing metal according to the embodiment is selected from the group consisting of: nickel (Ni), gold (Au), calcium (Ca), strontium (Sr), scandium (Sc), yttrium (Y), terbium (Tb), europium (Eu), cerium (Ce), praseodymium (Pr), ytterbium (Yb), holmium (Ho), erbium (Er), lanthanum (La), dysprosium (Dy), samarium (Sm), lutetium (Lu), thulium (Tm), neodymium (Nd), gadolinium (Gd), lithium (Li), iron (Fe), cadmium (Cd), or a combination thereof.
According to a more specific embodiment, the binary eutectic undergoes a binary eutectic solidification at a eutectic temperature >595 ℃ and <630 ℃. According to this embodiment, the fluidity-enhancing metal is selected from the group consisting of: calcium (Ca), cerium (Ce), lutetium (Lu), ytterbium (Yb), lithium (Li), or combinations thereof.
According to another more specific embodiment, the binary eutectic undergoes binary eutectic solidification at a eutectic temperature ≧ 630 ℃ and <645 ℃. In this embodiment, the fluidity-enhancing metal is selected from the group consisting of: nickel (Ni), dysprosium (Dy), europium (Eu), yttrium (Y), terbium (Tb), holmium (Ho), lanthanum (La), praseodymium (Pr), samarium (Sm), neodymium (Nd), or a combination thereof.
According to a more specific embodiment, the binary eutectic undergoes binary eutectic solidification at a eutectic temperature ≥ 645 deg.C and ≤ 660 deg.C. According to this embodiment, the fluidity-enhancing metal is selected from the group consisting of: gold (Au), strontium (Sr), scandium (Sc), erbium (Er), gadolinium (Gd), thulium (Tm), iron (Fe), cadmium (Cd), or combinations thereof.
According to various embodiments, the fluidity-enhancing metal is present at a hypoeutectic concentration. Referring back to FIG. 3A, composition XMaximum ofRepresents the maximum content of the fluidity enhancing metal when the binary alloy is solidified as a single-phase alloy.
According to some embodiments, the hypoeutectic concentration is such that the molten weld metal formed by the consumable welding electrode solidifies into a single phase having an aluminum (face centered cubic) crystal structure. However, embodiments are not so limited and in other embodiments, the molten weld metal formed from the consumable welding electrode solidifies into multiple phases including an aluminum crystal structure and at least one other phase including a flowability-enhancing metal.
The welding wire may include one or more of these elements, 0.01% -0.02%, 0.02% -0.05%, 0.05% -0.10%, 0.1% -0.2%, 0.2% -0.5%, 0.5% -1.0%, 1.0% -1.5%, 1.5% -2.0%, 2.0% -2.5%, 2.5% -3.0%, 3.0% -3.5%, 3.5% -4.0%, 4.0% -4.5%, 4.5% -5.0%, or a value within a range defined by any of these values, based on the total weight of the welding wire. In a particular embodiment, the fluidity enhancing metal is present in a form and hypoeutectic concentration of 0.05-0.5 wt% such that the solidification temperature range of the molten weld metal formed by melting the consumable welding electrode is less than 65 ℃.
In some of these embodiments, the mobility enhancing metal may be present in the form of an elemental metal. In some other of these embodiments, the fluidity-enhancing metal may be present in the form of: an oxide, halide, hydroxide, sulfide, sulfate, carbonate, phosphate, nitride, nitrite, nitride, carbide, boride, aluminide, telluride, or combinations thereof.
Structure of fluidity-enhanced welding electrode
FIG. 4A is a schematic illustration of a solid wire 40A configured to enhance weld metal flow, in accordance with an embodiment. In the illustrated embodiment, the mobility enhancing metal may be alloyed, e.g., formed as a solid solution, with the base metal composition such that the mobility enhancing metal present may form a metallic bond with the aluminum and other metallic elements of the base metal composition as described above. In these embodiments, the consumable welding electrode is a solid welding wire comprising a homogeneous solution or mixture, such as an alloy, formed from the base metal composition and the fluidity-enhancing metal.
Fig. 4B is a schematic illustration of a solid wire 40B configured to enhance weld metal flow, according to some other embodiments. Unlike solid wire 40A (FIG. 4A), in the embodiment shown in FIG. 4B, the mobility enhancing metal may be present in the form of a compound, such as an oxide, halide, hydroxide, sulfide, sulfate, carbonate, phosphate, nitride, nitrite, nitride, carbide, boride, aluminide, telluride, or combinations thereof. In these embodiments, the consumable welding electrode is a solid welding wire comprising a heterogeneous mixture formed from a base metal composition and a compound of a fluidity-enhancing metal. The compound of the fluidity enhancing metal may be present, for example, in the form of a powder dispersed in the matrix of the base metal composition.
Fig. 4C is a schematic illustration of a coated solid wire 42 configured to enhance the fluidity of the weld metal, in accordance with an embodiment. Fig. 4D is a schematic illustration of a cored welding wire 46 configured to enhance weld flowability, according to an embodiment. In these embodiments, the mobility enhancing metal may be chemically and/or physically separated from the base metal composition. For example, in a welding wire 42 (FIG. 4C), the fluidity enhancing metal may be present as a coating 44 formed on the outer surface of a core wire 43 formed from the base metal composition. The coating 44 may comprise a flow enhancing metal in an element, alloy or compound in a suitable form, such as a powder form. Alternatively, in the embodiment shown in FIG. 4D, the consumable wire 46 may be a cored wire comprising a core 48 and a sheath 49, wherein the core 48 comprises the fluidity-enhancing metal 47, for example, in powder form, and the sheath 49 comprises the base metal composition.
Method for enhancing fluidity in aluminum-based welding metal
Fig. 5 is a flowchart showing a method of enhancing the fluidity of a weld metal in an aluminum welding process according to an embodiment. The method includes providing 54 a consumable welding electrode comprising an aluminum-based base metal composition and a fluidity enhancing metal selected from the group consisting of: nickel (Ni), gold (Au), calcium (Ca), strontium (Sr), scandium (Sc), yttrium (Y), terbium (Tb), europium (Eu), cerium (Ce), praseodymium (Pr), ytterbium (Yb), holmium (Ho), erbium (Er), lanthanum (La), dysprosium (Dy), samarium (Sm), lutetium (Lu), thulium (Tm), neodymium (Nd), gadolinium (Gd), or a combination thereof. The consumable welding electrode may be according to any of the embodiments described above. The method additionally includes generating 58 an arc to form a fusion weld using the consumable welding electrode at a weld travel speed of 10-50 inches per minute. The fluidity enhancing metal is present in a form and amount such that the fluidity of the molten weld metal is higher relative to the molten weld metal formed under substantially the same welding conditions using the consumable welding electrode without the fluidity enhancing metal. The method illustrated in FIG. 5 may be implemented in any suitable welding process, including the gas-metal arc welding process described below by way of example.
In gas-metal arc welding using a solid electrode (GMAW) or a metal core electrode (GMAW-C), a shielding gas is used to provide shielding to the weld pool and the weld bead to prevent atmospheric contamination during the welding process. When solid electrodes are used, they are suitably alloyed with active ingredients that, in combination with a shielding gas as described above, can be designed to enhance weld metal flow while also providing low porosity or void-free welds having the desired physical and mechanical properties of the resulting weld metal. When a metal-cored electrode is used, some active ingredients (including fluidity-enhancing metals) may be added in the core of the cored wire and designed to provide similar functionality as in the case of a solid electrode.
Solid and metal core electrodes are designed to provide a solid, substantially pore-free weld metal with yield strength, tensile strength, ductility, and impact toughness under appropriate gas shielding to perform satisfactorily in the end application. The electrodes may also be designed to minimize the amount of slag generated during the welding process. For some applications, metal-cored electrodes may be used as a substitute for solid welding wire to improve productivity. As described herein, metal core electrodes refer to composite electrodes having a core that is at least partially filled and surrounded by a metal sheath. The core may include metal powders and active ingredients to aid in arc stability, weld wetting and appearance, and desired physical and mechanical properties. The metal core electrode was manufactured as follows: the ingredients of the core material are mixed and deposited inside the shaped strip, and the strip is then closed and stretched to the final diameter. For some applications, cored electrodes may provide increased deposition rates and wider, relatively consistent weld penetration profiles as compared to solid electrodes. As used herein, metal-cored electrode (GMAW-C) refers to an electrode having a core whose composition is primarily metal. When present, the non-metallic components in the core have a combined concentration of less than 5%, 3%, or 1% based on the total weight of each electrode. The relatively low non-metallic composition distinguishes GMAW-C electrodes from flux cored arc welding electrodes described in more detail below. GMAW-C electrodes may be characterized as: spray arc and high quality weld metal.
Similar to gas-metal arc welding using metal core electrodes (GMAW-C), electrodes for flux-cored arc welding (FCAW, FCAW-S, FCAW-G) also include a core surrounded by a sheath. That is, cored electrodes used in flux cored arc welding have a core that is at least partially filled and surrounded by a metal sheath, similar to the metal core electrodes described above. However, unlike metal cored electrodes (GMAW-C), cored electrodes for Flux Cored Arc Welding (FCAW) additionally include fluxes designed to provide protection to the weld pool and weld bead from atmospheric contamination during welding, at least in part replacing the shielding gas. Cored electrodes used in flux cored arc welding may additionally include other active ingredients to aid in arc stability, weld wetting and appearance, and desirable physical and mechanical properties. In one aspect, the flux cored arc electrode may be separated from the metallic core electrode region by the amount of non-metallic components present in the core, and the combined concentration of these non-metallic components may be less than 5%, 3%, or 1% based on the total weight of each electrode.
A number of flux compositions have been developed for flux cored electrodes to control arc stability, alter weld metal composition, and provide protection from atmospheric contamination. In flux cored electrodes, arc stability can be controlled by varying the composition of the flux. Therefore, it may be desirable to have a substance in the flux mixture that functions well as a plasma charge carrier. In some applications, the flux may also alter the weld metal composition by making impurities in the metal more readily fusible and providing a substance that may be combined with these impurities. Other materials are sometimes added to lower the slag melting point, improve the fluidity of the slag, and act as binders for the flux particles. The different wires used in FCAW may share some similar characteristics, e.g., forming a protective slag over the weld seam, using trailing angle techniques, being able to weld out of position or flat and level at higher deposition rates, being able to handle relatively higher amounts of contaminants on the plate, etc. On the other hand, there are different types of flux cored arc welding processes, namely: self-shielded flux-cored arc welding (FCAW-S) and gas-shielded flux-cored arc welding (FCAW-G).
FIG. 6 schematically illustrates an example of a Gas Metal Arc Welding (GMAW) system 110 configured for an aluminum-based welding wire, in accordance with an embodiment. GMAW system 110 includes a power source 112, a wire drive assembly 114, a shielding gas supply system 116, a cable assembly 118 for transmitting power, welding wire in a spool 124, and shielding gas in a shielding gas source 128 configured to be delivered to a workpiece 120 to be welded. Wire drive assembly 114 generally includes a spool support 122 for carrying a spool 124 that includes a continuous consumable wire electrode and a drive mechanism 126 that includes one or more drive wheels (not shown) for driving welding wire from spool 124 through cable assembly 118 to workpiece 120. The shielding gas supply system 116 generally includes a shielding gas source 128 and a gas supply conduit 130 in fluid communication with the cable assembly 118. As illustrated in fig. 6, the cable assembly 118 generally includes an elongated flexible cable 132 attached at one end to the power source 112, the wire drive assembly 114, and the gas supply system 116, and at the other end to a welding gun 134.
Further examples
1. A consumable welding electrode, comprising:
a base metal composition comprising at least 70% by weight of aluminum; and
a fluidity enhancing metal capable of forming a binary eutectic composition with aluminum, wherein the binary eutectic composition undergoes binary eutectic solidification at a eutectic temperature less than 90 ℃ below the melting point of pure aluminum,
wherein the fluidity-enhancing metal is present in a form and in an amount such that a weld metal formed from the consumable welding electrode has one or more of the following relative to a weld metal formed under substantially identical welding conditions using a consumable welding electrode without the fluidity-enhancing metal:
the weld metal height (H) is at least 5% lower,
the weld metal width (W) is at least 5% greater,
the H/W ratio is at least 5% less,
a degree of penetration (P) of at least 5% less, and
the weld toe angle (q) is at least 5% less.
2. A consumable welding electrode, comprising:
a base metal composition comprising at least 70% by weight of aluminum; and
a fluidity enhancing metal capable of forming a binary eutectic composition with aluminum, wherein the binary eutectic composition undergoes binary eutectic solidification at a eutectic temperature less than 90 ℃ below the melting point of pure aluminum,
wherein the fluidity enhancing metal is present in a form and in an amount such that the molten weld metal formed by the consumable welding electrode has a fluidity that is at least 5% higher relative to the fluidity of molten weld metal formed under substantially identical welding conditions using a consumable welding electrode without the fluidity enhancing metal.
3. A consumable welding electrode, comprising:
a base metal composition comprising at least 70% by weight of aluminum; and
a fluidity enhancing metal selected from the group consisting of: nickel (Ni), gold (Au), calcium (Ca), strontium (Sr), scandium (Sc), yttrium (Y), terbium (Tb), europium (Eu), cerium (Ce), praseodymium (Pr), ytterbium (Yb), holmium (Ho), erbium (Er), lanthanum (La), dysprosium (Dy), samarium (Sm), lutetium (Lu), thulium (Tm), neodymium (Nd), gadolinium (Gd), or combinations thereof,
wherein the flowability enhancing metal is present in an amount greater than 0.05% by weight and less than or equal to the binary eutectic composition based on the combined weight of aluminum and the flowability enhancing metal.
4. A consumable welding electrode, comprising:
a base metal composition comprising at least 70% by weight of aluminum; and
a fluidity-enhancing metal selected from the group consisting of: nickel (Ni), gold (Au), calcium (Ca), strontium (Sr), scandium (Sc), yttrium (Y), terbium (Tb), europium (Eu), cerium (Ce), praseodymium (Pr), ytterbium (Yb), holmium (Ho), erbium (Er), lanthanum (La), dysprosium (Dy), samarium (Sm), lutetium (Lu), thulium (Tm), neodymium (Nd), gadolinium (Gd), or combinations thereof,
wherein the fluidity enhancing metal is present in a form and in an amount such that the molten weld metal formed by the consumable welding electrode has a fluidity that is at least 5% higher relative to the fluidity of molten weld metal formed under substantially identical welding conditions using a consumable welding electrode without the fluidity enhancing metal.
5. A consumable welding electrode, comprising:
a base metal composition comprising at least 70% by weight of aluminum; and
a fluidity-enhancing metal selected from the group consisting of: nickel (Ni), gold (Au), calcium (Ca), strontium (Sr), scandium (Sc), yttrium (Y), terbium (Tb), europium (Eu), cerium (Ce), praseodymium (Pr), ytterbium (Yb), holmium (Ho), erbium (Er), lanthanum (La), dysprosium (Dy), samarium (Sm), lutetium (Lu), thulium (Tm), neodymium (Nd), gadolinium (Gd), or combinations thereof,
wherein the fluidity-enhancing metal is present in a form and in an amount such that a weld metal formed from the consumable welding electrode has one or more of the following relative to a weld metal formed under substantially identical welding conditions using a consumable welding electrode without the fluidity-enhancing metal:
the weld metal height (H) is at least 5% lower,
the weld metal width (W) is at least 5% greater,
the H/W ratio is at least 5% less,
a degree of penetration (P) of at least 5% less, and
the weld toe angle (q) is at least 5% less.
6. The consumable welding electrode of any of the preceding embodiments, wherein the fluidity enhancing metal selected from the group consisting of aluminum and the fluidity enhancing metal is present in an amount greater than 0.1% by weight and less than or equal to the eutectic composition, based on the combined weight of aluminum and the fluidity enhancing metal: nickel (Ni), gold (Au), calcium (Ca), strontium (Sr), scandium (Sc), yttrium (Y), terbium (Tb), europium (Eu), cerium (Ce), praseodymium (Pr), ytterbium (Yb), holmium (Ho), erbium (Er), lanthanum (La), dysprosium (Dy), samarium (Sm), lutetium (Lu), thulium (Tm), neodymium (Nd), gadolinium (Gd), or a combination thereof.
7. The consumable welding electrode of any one of the embodiments, wherein the mobility enhancing metal is capable of forming a binary eutectic composition with aluminum, wherein the binary eutectic composition undergoes a binary eutectic solidification at a eutectic temperature of 570-660 ℃.
8. The consumable welding electrode of any of the above embodiments, wherein the fluidity enhancing metal is present in a form and in an amount such that a molten weld metal formed from the consumable welding electrode has a fluidity that is at least 10% higher relative to a molten weld metal formed using a base metal composition without the fluidity enhancing metal.
9. The consumable welding electrode of any one of the preceding embodiments, wherein the base metal composition further comprises one or both of silicon (Si) and magnesium (Mg) as alloying elements for alloying with aluminum in a metal weld formed using the consumable welding electrode.
10. The consumable welding electrode of any one of the above embodiments, wherein the yield strength and/or tensile strength of the solidified weld metal formed from the consumable welding electrode is greater than or within 10% of the yield strength and/or tensile strength of the solidified weld metal formed using the base metal composition without the fluidity enhancing metal.
11. The consumable welding electrode of any one of the preceding embodiments, wherein the mobility-enhancing metal is present in elemental metallic form.
12. The consumable welding electrode of any one of the preceding embodiments, wherein the mobility enhancing metal is present in a compound selected from an oxide, a halide, a hydroxide, a sulfide, a sulfate, a carbonate, a phosphate, a nitride, a nitrite, a nitride, a carbide, a boride, an aluminide, a telluride, or combinations thereof.
13. The consumable welding electrode of any of the above embodiments, wherein the welding electrode is designed to weld under welding conditions at a weld travel speed of 10-50 inches per minute.
14. The consumable welding electrode of any of the above embodiments, wherein the welding electrode is designed for Gas Metal Arc Welding (GMAW).
15. The consumable welding electrode of any one of the preceding embodiments, wherein the consumable welding electrode comprises a core wire comprising the base metal composition and a coating comprising a fluidity-enhancing metal surrounding the core wire.
16. The consumable welding electrode of any one of embodiments 1-14 wherein the consumable welding electrode is a cored welding wire comprising a core and a sheath, wherein the core comprises the flowability-enhancing metal and the sheath comprises the base metal composition.
17. The consumable welding electrode of any one of embodiments 1-14, wherein the consumable welding electrode is a solid welding wire comprising a homogeneous mixture of a base metal composition and a fluidity-enhancing metal.
18. A method of welding an aluminum workpiece, comprising:
providing a consumable welding electrode comprising an aluminum-based base metal composition and a fluidity-enhancing metal selected from the group consisting of: nickel (Ni), gold (Au), calcium (Ca), strontium (Sr), scandium (Sc), yttrium (Y), terbium (Tb), europium (Eu), cerium (Ce), praseodymium (Pr), ytterbium (Yb), holmium (Ho), erbium (Er), lanthanum (La), dysprosium (Dy), samarium (Sm), lutetium (Lu), thulium (Tm), neodymium (Nd), gadolinium (Gd), or a combination thereof; and
the consumable welding electrode is used to generate an arc to form molten weld metal at a weld travel speed of 10-50 inches per minute,
wherein the fluidity enhancing metal is present in a form and in an amount such that the molten weld metal has a higher fluidity relative to molten weld metal formed under substantially the same welding conditions using a consumable welding electrode without the fluidity enhancing metal.
19. The welding method of embodiment 18, wherein the consumable wire is as in any one of embodiments 1-17.
Throughout the specification and claims, the words "comprise", "comprising", "including", "comprises", "comprising", and the like are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense, unless the context clearly requires otherwise; i.e., in the sense of "including, but not limited to". As generally used herein, the term "coupled" refers to two or more elements that may be connected directly or through one or more intermediate elements. Likewise, the word "connected," as generally used herein, refers to two or more elements that may be connected directly or through one or more intermediate elements. Additionally, as used in this application, the terms "herein," "above," "below," and words of similar import shall refer to this application as a whole and not to any particular portions of this application. Words in the above detailed description using the singular or plural number may also include the plural or singular number, respectively, where the context permits. The word "or" in a list referring to two or more items covers all of the following interpretations of the word: any item in the list, all items in the list, and any combination of items in the list.
Furthermore, unless specifically stated otherwise, or otherwise understood within the context of use, conditional language (such as "may", "can", "may", "might", "mighty", "might", "e.g. (e.g.)", "e.g. (for example)", "such as (sucas)", etc.), as used herein, is generally intended to convey that certain embodiments include certain features, elements and/or steps, while other embodiments do not include certain features, elements and/or steps. Such conditional language is not generally intended to imply: such features, elements, and/or statements are required in any way for one or more embodiments or whether such features, elements, and/or statements are included in or are to be performed in any particular embodiment.
While certain embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the disclosure. Indeed, the novel apparatus, methods, and systems described herein may be embodied in various other forms; furthermore, various omissions, substitutions and changes in the form of the methods and systems described herein may be made without departing from the spirit of the disclosure. For example, while blocks are presented in a given arrangement, alternative embodiments may perform similar functions with different components and/or circuit topologies, and some blocks may be deleted, moved, added, subdivided, combined, and/or modified. Each of these blocks may be implemented in a variety of different ways. Any suitable combination of the elements and acts of the different embodiments described above may be combined to provide further embodiments. The various features and processes described above may be implemented independently of one another or may be combined in various ways. All possible combinations and subcombinations of the features of the disclosure are intended to fall within the scope of the disclosure.
Claims (37)
1. A consumable welding electrode, comprising:
a base metal composition comprising at least 70% by weight of aluminum; and
a fluidity enhancing metal capable of forming a binary eutectic with aluminum, wherein the binary eutectic undergoes binary eutectic solidification at a eutectic temperature of 595-660 ℃,
wherein the fluidity enhancing metal is present in a form and hypoeutectic concentration of 0.05 to 0.5 weight percent such that a solidification temperature range of molten weld metal formed by melting the consumable welding electrode is less than 65 ℃.
2. The consumable welding electrode of claim 2, wherein the binary eutectic undergoes binary eutectic solidification at a eutectic temperature >595 ℃ and <630 ℃.
3. The consumable welding electrode of claim 3, wherein the fluidity-enhancing metal is selected from the group consisting of: calcium (Ca), cerium (Ce), lutetium (Lu), ytterbium (Yb), lithium (Li), or combinations thereof.
4. The consumable welding electrode of claim 2, wherein the binary eutectic undergoes binary eutectic solidification at a eutectic temperature of ≥ 630 ℃ and <645 ℃.
5. The consumable welding electrode of claim 4, wherein the fluidity-enhancing metal is selected from the group consisting of: nickel (Ni), dysprosium (Dy), europium (Eu), yttrium (Y), terbium (Tb), holmium (Ho), lanthanum (La), praseodymium (Pr), samarium (Sm), neodymium (Nd), or a combination thereof.
6. The consumable welding electrode of claim 2, wherein the binary eutectic undergoes binary eutectic solidification at a eutectic temperature of ≥ 645 ℃ and ≤ 660 ℃.
7. The consumable welding electrode of claim 6, wherein the fluidity-enhancing metal is selected from the group consisting of: gold (Au), strontium (Sr), scandium (Sc), erbium (Er), gadolinium (Gd), thulium (Tm), iron (Fe), cadmium (Cd), or combinations thereof.
8. The consumable welding electrode of claim 1, wherein a weld metal formed from the consumable welding electrode has one or more of the following relative to a weld metal formed under substantially identical welding conditions using a consumable welding electrode without the flowability-enhancing metal, having the same base metal composition:
the weld metal height (H) is at least 5% lower,
the weld metal width (W) is at least 5% greater,
the H/W ratio is at least 5% less,
a degree of penetration (P) of at least 5% less, and
the weld toe angle (q) is at least 5% less.
9. The consumable welding electrode of claim 1, wherein the fluidity enhancing metal is present in elemental form or forms a metal alloy with an element of the base metal.
10. The consumable welding electrode of claim 1, wherein the mobility enhancing metal is present in the form of a compound selected from the group consisting of oxides, halides, hydroxides, sulfides, sulfates, carbonates, phosphates, nitrides, nitrites, nitrides, carbides, borides, aluminides, tellurides, or combinations thereof.
11. The consumable welding electrode of claim 10, wherein the mobility enhancing metal is present in the form of an oxide or hydroxide.
12. The consumable welding electrode of claim 1, wherein the fluidity enhancing metal is present in a form and a hypoeutectic concentration such that a molten weld metal formed from the consumable welding electrode has a fluidity that is at least 5% higher relative to a molten weld metal formed under substantially identical welding conditions using a consumable welding electrode having the same base metal composition without the fluidity enhancing metal.
13. A consumable welding electrode, comprising:
a base metal composition comprising at least 70% by weight of aluminum; and
a fluidity enhancing metal capable of forming a binary eutectic with aluminum, wherein the binary eutectic undergoes binary eutectic solidification at a eutectic temperature of 595-660 ℃,
wherein the mobility enhancing metal is present in the form of a compound selected from the group consisting of oxides, halides, hydroxides, sulfides, sulfates, carbonates, phosphates, nitrides, nitrites, nitrides, carbides, borides, aluminides, tellurides, or combinations thereof.
14. The consumable welding electrode of claim 13, wherein the fluidity-enhancing metal is selected from the group consisting of: nickel (Ni), gold (Au), calcium (Ca), strontium (Sr), scandium (Sc), yttrium (Y), terbium (Tb), europium (Eu), cerium (Ce), praseodymium (Pr), ytterbium (Yb), holmium (Ho), erbium (Er), lanthanum (La), dysprosium (Dy), samarium (Sm), lutetium (Lu), thulium (Tm), neodymium (Nd), gadolinium (Gd), lithium (Li), iron (Fe), cadmium (Cd), or a combination thereof.
15. The consumable welding electrode of claim 14, wherein the binary eutectic undergoes binary eutectic solidification at a eutectic temperature >595 ℃ and <630 ℃.
16. The consumable welding electrode of claim 15, wherein the fluidity-enhancing metal is selected from the group consisting of: calcium (Ca), cerium (Ce), lutetium (Lu), ytterbium (Yb), lithium (Li), or combinations thereof.
17. The consumable welding electrode of claim 14, wherein the binary eutectic undergoes binary eutectic solidification at a eutectic temperature of ≥ 630 ℃ and <645 ℃.
18. The consumable welding electrode of claim 17, wherein the fluidity-enhancing metal is selected from the group consisting of: nickel (Ni), dysprosium (Dy), europium (Eu), yttrium (Y), terbium (Tb), holmium (Ho), lanthanum (La), praseodymium (Pr), samarium (Sm), neodymium (Nd), or a combination thereof.
19. The consumable welding electrode of claim 14, wherein the binary eutectic undergoes binary eutectic solidification at a eutectic temperature of ≥ 645 ℃ and ≤ 660 ℃.
20. The consumable welding electrode of claim 19, wherein the fluidity-enhancing metal is selected from the group consisting of: gold (Au), strontium (Sr), scandium (Sc), erbium (Er), gadolinium (Gd), thulium (Tm), iron (Fe), cadmium (Cd), or combinations thereof.
21. The consumable welding electrode of claim 14, wherein the fluidity enhancing metal is present at a hypoeutectic concentration of 0.05-0.5 wt% such that a solidification temperature range of molten weld metal formed by melting the consumable welding electrode is less than 65 ℃.
22. The consumable welding electrode of claim 14, wherein the base metal composition further comprises one or both of silicon (Si) and magnesium (Mg) as alloying elements for alloying with aluminum in a weld metal formed using the consumable welding electrode.
23. A consumable welding electrode, comprising:
a base metal composition comprising at least 70% by weight of aluminum; and
a fluidity enhancing metal capable of forming a binary eutectic with aluminum, wherein the binary eutectic undergoes binary eutectic solidification at a eutectic temperature of 595-660 ℃,
wherein the fluidity enhancing metal is present in a form and a hypoeutectic concentration such that a molten weld metal formed from the consumable welding electrode has a fluidity that is at least 5% higher relative to a molten weld metal formed under substantially identical welding conditions using a consumable welding electrode of the same base metal composition without the fluidity enhancing metal.
24. The consumable welding electrode of claim 23, wherein the hypoeutectic concentration causes molten weld metal formed from the consumable welding electrode to solidify into a single phase having an aluminum crystal structure.
25. The consumable welding electrode of claim 24, wherein the fluidity enhancing metal is present in an amount of 0.05-0.50 wt%.
26. The consumable welding electrode of claim 23, wherein the mobility enhancing metal is present in a compound selected from an oxide, a halide, a hydroxide, a sulfide, a sulfate, a carbonate, a phosphate, a nitride, a nitrite, a nitride, a carbide, a boride, an aluminide, a telluride, or combinations thereof.
27. The consumable welding electrode of claim 23, wherein the fluidity-enhancing metal is selected from the group consisting of: nickel (Ni), gold (Au), calcium (Ca), strontium (Sr), scandium (Sc), yttrium (Y), terbium (Tb), europium (Eu), cerium (Ce), praseodymium (Pr), ytterbium (Yb), holmium (Ho), erbium (Er), lanthanum (La), dysprosium (Dy), samarium (Sm), lutetium (Lu), thulium (Tm), neodymium (Nd), gadolinium (Gd), lithium (Li), iron (Fe), cadmium (Cd), or a combination thereof.
28. The consumable welding electrode of claim 27, wherein the binary eutectic undergoes binary eutectic solidification at a eutectic temperature >595 ℃ and <630 ℃.
29. The consumable welding electrode of claim 28, wherein the fluidity-enhancing metal is selected from the group consisting of: calcium (Ca), cerium (Ce), lutetium (Lu), ytterbium (Yb), lithium (Li), or combinations thereof.
30. The consumable welding electrode of claim 27, wherein the binary eutectic undergoes binary eutectic solidification at a eutectic temperature of ≥ 630 ℃ and <645 ℃.
31. The consumable welding electrode of claim 30, wherein the fluidity-enhancing metal is selected from the group consisting of: nickel (Ni), dysprosium (Dy), europium (Eu), yttrium (Y), terbium (Tb), holmium (Ho), lanthanum (La), praseodymium (Pr), samarium (Sm), neodymium (Nd), or a combination thereof.
32. The consumable welding electrode of claim 27, wherein the binary eutectic undergoes binary eutectic solidification at a eutectic temperature of ≥ 645 ℃ and ≤ 660 ℃.
33. The consumable welding electrode of claim 32, wherein the fluidity-enhancing metal is selected from the group consisting of: gold (Au), strontium (Sr), scandium (Sc), erbium (Er), gadolinium (Gd), thulium (Tm), iron (Fe), cadmium (Cd), or combinations thereof.
34. The consumable welding electrode of claim 23, wherein the base metal composition further comprises one or both of silicon (Si) and magnesium (Mg) as alloying elements for alloying with aluminum in a weld metal formed using the consumable welding electrode.
35. The consumable welding electrode of claim 23, wherein the consumable welding electrode is a coated electrode comprising a core wire comprising the base metal composition and a coating comprising a fluidity-enhancing metal surrounding the core wire.
36. The consumable welding electrode of claim 23, wherein the consumable welding electrode is a cored welding wire comprising a core and a sheath, wherein the core comprises the fluidity enhancing metal and the sheath comprises the base metal composition.
37. The consumable welding electrode of claim 23, wherein the consumable welding electrode is a solid wire comprising a homogeneous mixture of the base metal composition and the fluidity-enhancing metal.
Applications Claiming Priority (6)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US202063090867P | 2020-10-13 | 2020-10-13 | |
| US63/090,867 | 2020-10-13 | ||
| US17/464,535 US11999019B2 (en) | 2020-09-22 | 2021-09-01 | Aluminum-based welding electrodes |
| US17/464,535 | 2021-09-01 | ||
| US17/446,778 | 2021-09-02 | ||
| US17/446,778 US20220097179A1 (en) | 2020-09-22 | 2021-09-02 | Aluminum-based welding electrodes |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN114346385A true CN114346385A (en) | 2022-04-15 |
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Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202111195066.7A Pending CN114346385A (en) | 2020-10-13 | 2021-10-12 | Aluminum-based welding electrode |
Country Status (4)
| Country | Link |
|---|---|
| JP (1) | JP2022064321A (en) |
| CN (1) | CN114346385A (en) |
| CA (1) | CA3136184A1 (en) |
| MX (1) | MX2021012482A (en) |
-
2021
- 2021-10-08 CA CA3136184A patent/CA3136184A1/en active Pending
- 2021-10-11 MX MX2021012482A patent/MX2021012482A/en unknown
- 2021-10-12 CN CN202111195066.7A patent/CN114346385A/en active Pending
- 2021-10-12 JP JP2021167148A patent/JP2022064321A/en active Pending
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| Publication number | Publication date |
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| MX2021012482A (en) | 2022-04-14 |
| JP2022064321A (en) | 2022-04-25 |
| CA3136184A1 (en) | 2022-04-13 |
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