WO2010060021A1 - Alliages de charge soudables par fusion - Google Patents

Alliages de charge soudables par fusion Download PDF

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Publication number
WO2010060021A1
WO2010060021A1 PCT/US2009/065486 US2009065486W WO2010060021A1 WO 2010060021 A1 WO2010060021 A1 WO 2010060021A1 US 2009065486 W US2009065486 W US 2009065486W WO 2010060021 A1 WO2010060021 A1 WO 2010060021A1
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WO
WIPO (PCT)
Prior art keywords
alloy
weld
aluminum
weld filler
base metal
Prior art date
Application number
PCT/US2009/065486
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English (en)
Inventor
Jen C. Lin
Israel Stol
Kyle L. Williams
Original Assignee
Alcoa Inc.
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Publication date
Application filed by Alcoa Inc. filed Critical Alcoa Inc.
Publication of WO2010060021A1 publication Critical patent/WO2010060021A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24—Selection of soldering or welding materials proper
    • B23K35/28—Selection of soldering or welding materials proper with the principal constituent melting at less than 950 degrees C
    • B23K35/286—Al as the principal constituent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K10/00—Welding or cutting by means of a plasma
    • B23K10/02—Plasma welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K15/00—Electron-beam welding or cutting
    • B23K15/0046—Welding
    • B23K15/0093—Welding characterised by the properties of the materials to be welded
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/22—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded
    • B23K20/233—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded without ferrous layer
    • B23K20/2336—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded without ferrous layer both layers being aluminium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/20—Bonding
    • B23K26/21—Bonding by welding
    • B23K26/211—Bonding by welding with interposition of special material to facilitate connection of the parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/20—Bonding
    • B23K26/32—Bonding taking account of the properties of the material involved
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/34—Laser welding for purposes other than joining
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/02—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape
    • B23K35/0255—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape for use in welding
    • B23K35/0261—Rods, electrodes, wires
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24—Selection of soldering or welding materials proper
    • B23K35/28—Selection of soldering or welding materials proper with the principal constituent melting at less than 950 degrees C
    • B23K35/286—Al as the principal constituent
    • B23K35/288—Al as the principal constituent with Sn or Zn
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/23—Arc welding or cutting taking account of the properties of the materials to be welded
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/01—Layered products comprising a layer of metal all layers being exclusively metallic
    • B32B15/016—Layered products comprising a layer of metal all layers being exclusively metallic all layers being formed of aluminium or aluminium alloys
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/06—Alloys based on aluminium with magnesium as the next major constituent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/08—Non-ferrous metals or alloys
    • B23K2103/10—Aluminium or alloys thereof
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/12—All metal or with adjacent metals
    • Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
    • Y10T428/12736—Al-base component
    • Y10T428/12764—Next to Al-base component

Definitions

  • Aluminum base metals are used in a variety of industries including marine, defense, automotive, railroad, transportation, aerospace, liquefied natural gas, oil and gas, among others. Common to all of these industries is the need to weld parts together with fusion based and/or solid state based welding processes.
  • the present disclosure relates to improved weld filler alloys useful in welding 2xxx, 5xxx, 6xxx and/or 7xxx wrought aluminum alloys.
  • the weld filler alloy embodiments disclosed herein may be utilized in the following industries including without limitation: (a) marine (e.g., ship hulls and other sub-structures), (b) defense (e.g., armored vehicles for high strength and/or blast resistance), (c) aerospace (e.g., plane wings fabricated out of Aluminum Association (AA) 2099 aluminum alloy or AA 7085 aluminum alloy, among other 2xxx and/or 7xxx series aluminum alloys according to the AA designation), (d) automotive, rail and transportation (e.g., sub-structures fabricated out of 6013 aluminum alloy or AA 5083 aluminum alloy, among other 6xxx and/or 5xxx series aluminum alloys and/or extrusions welded together), and (e) oil and gas (e.g., risers and oil platforms produced out of 7xxx series aluminum alloys
  • the weld filler alloy embodiments may be utilized in the welding of parts (e.g., plates, extrusions, sheets, forgings) using fusion-based welding processes (e.g., gas metal arc welding, gas tungsten arc welding) and/or solid-state based welding processes (e.g., friction stir welding, friction welding).
  • fusion-based welding processes e.g., gas metal arc welding, gas tungsten arc welding
  • solid-state based welding processes e.g., friction stir welding, friction welding.
  • the weld filler alloy is in the form of a wire or a rod. In one embodiment, the weld filler alloy has a solidus temperature that is lower than the solidus temperature of the aluminum base metal segments or the aluminum base metals. In one embodiment, the weld filler alloy has a solidus temperature that is lower than the solidus temperature of the aluminum base metal segments or the aluminum base metals.
  • the weld filler alloy upon fusion welding and dilution with the base metal segments or base metals being welded together, results in a weld metal whose solidus temperature is lower than the solidus temperatures of the base metal segments or each of the base metals being welded together, at any solid/liquid fraction during the solidification of the weld.
  • a weld filler alloy includes from about 5.6 wt. % Mg to about
  • the weld filler alloy includes from about 5.6 wt. % Mg to about 6.2 wt. % Mg. In one embodiment, the weld filler alloy includes about 5.9 wt. % Mg.
  • the weld filler alloy includes from about 0.05 wt. % Zn to about 3.5 wt. % Zn. In one embodiment, the weld filler alloy includes from about 1.7 wt. %
  • the weld filler alloy includes about 2.0 wt. %
  • the grain refiner is at least one of Zr, Ti and B.
  • the weld filler alloy is substantially free of Mn.
  • a weld filler alloy consists essentially of from about 5.6 wt. %
  • Mg to about 8.0 wt. % Mg, from about 0.01 wt. % to about 0.5 wt. % of a grain refiner, and the balance aluminum, incidental elements and impurities.
  • a weld filler alloy consists essentially of from about 5.6 wt. %
  • an aluminum alloy product includes a first aluminum alloy segment, a second aluminum alloy segment, and a weldment joining the first aluminum alloy segment to the second aluminum alloy segment, where the weldment includes a weld filler alloy having from about 5.6 wt. % Mg to about 8.0 wt. % Mg, from about 0.01 wt. % to about
  • the weld filler alloy includes from about 0.05 wt. % Zn to about 3.5 wt. % Zn.
  • each of the first aluminum alloy segment and the second aluminum alloy segment is at least one of a 6xxx, 5xxx, 7xxx and 2xxx series aluminum alloy.
  • the weldment achieves cracks of not greater than about
  • a method of welding aluminum products includes (a) providing first aluminum product and second aluminum product proximal to each other, (b) providing a weld filler alloy proximal to the first aluminum product and the second aluminum product, where the weld filler alloy includes from about 5.6 wt. % Mg to about 8.0 wt. % Mg, from about 0.01 wt. % to about 0.5 wt. % of a grain refiner, and up to about 94.4 wt.
  • FIG. 1 illustrates a comparison of solidus temperatures between an AA 7085 aluminum alloy base metal and weldments produced with an AA 5356 weld filler alloy at different solid/liquid fractions, with varying percentage of dilution of the AA 7085 base metal and the AA 5356 weld filler alloy within the weldments;
  • FIG. 2 illustrates a comparison of solidus temperatures between an AA 7085 aluminum alloy base metal and weldments produced with an AA 5183 weld filler alloy at different solid/liquid fractions, with varying percentage of dilution of the AA 7085 base metal and the AA 5183 weld filler alloy within the weldments;
  • FIG. 3 illustrates a comparison of solidus temperatures between an AA 7085 aluminum alloy base metal and weldments produced with an AA 5556 weld filler alloy at different solid/liquid fractions, with varying percentage of dilution of the AA 7085 base metal and the AA 5556 weld filler alloy within the weldments;
  • FIG. 4 illustrates a comparison of solidus temperatures between an AA 7085 aluminum alloy base metal and weldments produced with an AA 4043 weld filler alloy at different solid/liquid fractions, with varying percentage of dilution of the AA 7085 base metal and the AA 4043 weld filler alloy within the weldments;
  • FIG. 5 illustrates a comparison of solidus temperatures between an AA 7085 aluminum alloy base metal and weldments produced with an AA 4145 weld filler alloy at different solid/liquid fractions, with varying percentage of dilution of the AA 7085 base metal and the AA 4145 weld filler alloy within the weldments;
  • FIG. 6 illustrates a comparison of solidus temperatures between an AA 7085 aluminum alloy base metal and weldments produced with Al-Mg weld filler alloy according to one embodiment of the present disclosure at different solid/liquid fractions, with varying percentage of dilution of the AA 7085 base metal and the Al-Mg weld filler alloy within the weldments;
  • FIGS. 7A and 7B are etched and anodized cross-sectional micrographs, respectively, of a weldment produced with an AA 7085 aluminum alloy base metal and an
  • FIGS. 8A and 8B are etched and anodized cross-sectional micrographs, respectively, of a weldment produced with a modified AA 7085 aluminum alloy base metal and an Al-Mg weld filler wire in accordance with one embodiment of the present disclosure;
  • FIG. 9 is a photograph of an end-constrained double tee-fillet weldment produced with an AA 7085 aluminum alloy base metal and an AA 5356 aluminum alloy filler wire;
  • FIG. 10 is a photograph of an end-constrained double tee-fillet weldment produced with a modified AA 7085 aluminum alloy base metal and an Al-Mg weld filler wire in accordance with one embodiment of the present disclosure
  • FIG. 11 is a cross-sectional macrograph through a weldment produced with an AA
  • FIG. 12 is a cross-sectional macrograph through a weldment produced with a modified AA 7085 aluminum alloy base metal and an Al-Mg weld filler wire in accordance with one embodiment of the present disclosure
  • FIG. 13 illustrates a comparison of solidus temperatures between an AA 6013 aluminum alloy base metal and weldments produced with an AA 5356 weld filler alloy at different solid/liquid fractions, with varying percentage of dilution of the AA 6013 base metal and the AA 5356 weld filler alloy within the weldments;
  • FIG. 14 illustrates a comparison of solidus temperatures between an AA 6013 aluminum alloy base metal and weldments produced with Al-Mg weld filler alloy according to one embodiment of the present disclosure at different solid/liquid fractions, with varying percentage of dilution of the AA 6013 base metal and the Al-Mg weld filler alloy within the weldments;
  • FIG. 15 is a cross-sectional micrograph of a weldment produced with an AA 6013 aluminum alloy base metal and an AA 5356 aluminum alloy weld filler wire;
  • FIG. 16 is a cross-sectional micrograph a weldment produced with an AA 6013 aluminum alloy base metal and an Al-Mg weld filler wire in accordance with one embodiment of the present disclosure;
  • FIGS. 17A-17D are two sets of cross-sectional micrographs of weldments produced with an AA 6013 aluminum alloy and an AA 5356 weld filler wire;
  • FIGS. 18A-18D are two sets of cross-sectional micrographs of weldments produced with an AA 6013 aluminum alloy and a modified AA 5356 weld filler wire;
  • FIGS. 19A-19D are two sets of cross-sectional micrographs of weldments produced with an AA 6013 aluminum alloy and an AA 4043 weld filler wire;
  • FIGS. 2OA and 2OB are cross-sectional micrographs of a weldment produced with an AA 6013 aluminum alloy and an Al-Mg weld filler wire in accordance with one embodiment of the present disclosure
  • FIG. 21 illustrates a comparison of solidus temperatures between an AA 2099 aluminum alloy base metal and weldments produced with an AA 4043 weld filler alloy at different solid/liquid fractions, with varying percentage of dilution of the AA 2099 base metal and the AA 4043 weld filler alloy within the weldments;
  • FIG. 22 illustrates a comparison of solidus temperatures between an AA 2099 aluminum alloy base metal and weldments produced with an AA 4145 weld filler alloy at different solid/liquid fractions, with varying percentage of dilution of the AA 2099 base metal and the AA 4145 weld filler alloy within the weldments;
  • FIG. 23 illustrates a comparison of solidus temperatures between an AA 2099 aluminum alloy base metal and weldments produced with an AA 5356 weld filler alloy at different solid/liquid fractions, with varying percentage of dilution of the AA 2099 base metal and the AA 5356 weld filler alloy within the weldments;
  • FIG. 24 illustrates a comparison of solidus temperatures between an AA 2099 aluminum alloy base metal and weldments produced with Al-Mg weld filler alloy according to one embodiment of the present disclosure at different solid/liquid fractions, with varying percentage of dilution of the AA 2099 base metal and the Al-Mg weld filler alloy within the weldments;
  • FIG. 25 illustrates a comparison of solidus temperatures between an AA 2099 aluminum alloy base metal and weldments produced with Al-Mg-Zn weld filler alloy according to one embodiment of the present disclosure at different solid/liquid fractions, with varying percentage of dilution of the AA 2099 base metal and the Al-Mg-Zn weld filler alloy within the weldments;
  • FIG. 26 comprises a plurality of photographs of bend specimens of AA 6013 aluminum alloy base metal welded with an AA 4043 weld filler alloy;
  • FIG. 27 comprises a plurality of photographs of bend specimens of AA 6013 aluminum alloy base metal welded with an Al-Mg weld filler alloy according to one embodiment of the present disclosure.
  • any numerical range of values such ranges are understood to include each and every number and/or fraction between the stated range minimum and maximum.
  • thermal treatment practice e.g., temperature
  • elemental range set forth herein set forth herein.
  • Aluminum alloys including the likes of AA 7085, AA 7040, AA 7140, AA 6013,
  • AA 5083 and AA 2099 may present challenges in welding to other aluminum alloys or to each other (e.g., repairing or joining two similar segments together). For example, it may be challenging to weld a first AA 7085 aluminum alloy base metal segment to a second AA 7085 aluminum alloy base metal segment, or to weld an AA 6013 aluminum alloy base metal segment to an AA 5083 aluminum alloy base metal segment, with conventional fusion-based welding processes (e.g., gas tungsten arc welding (GTAW), gas metal arc welding (GMAW)) because of hot cracking and solidification.
  • GTAW gas tungsten arc welding
  • GMAW gas metal arc welding
  • AA 7085 means aluminum alloy 7085 as defined by the
  • AA 2099 mean aluminum alloys 7040, 7140, 6013, 5083 and 2099, respectively, as defined by the Aluminum Association Teal Sheets.
  • base metal means the aluminum parts (e.g., plates, sheets, extrusions, forgings) to be welded.
  • Types of base metals that may be used in the present disclosure include, but are not limited to, 2xxx, 5xxx, 6xxx, and 7xxx series aluminum alloys (Aluminum Association designations).
  • 2xxx means aluminum alloys of the 2xxx series as designated by the Aluminum Association.
  • 5xxx means aluminum alloys of the 5xxx, 6xxx and 7xxx series, respectively, as designated by the Aluminum Association.
  • the present disclosure relates to Al-Mg weld filler alloys and methods of using the same. In one embodiment, the present disclosure relates to Al-Mg-Zn weld filler alloys and methods of using the same.
  • the weld filler alloys may facilitate improved welding characteristics, such as when employed with at least one of Al-Cu alloy product, Al-Mg alloy product, Al-Mg-Si alloy product and Al-Zn/Cu alloy product.
  • welding filler alloy means an alloy added to a molten pool formed at a joint between the base metals being welded together for providing a desired composition, geometry and size of a weld (e.g., weldment) upon solidification.
  • weld, weldment and weld deposit can be used interchangeably to represent a weld.
  • Examples of Al-Cu alloy product include any of the AA 2xxx series alloys. In one example, the Al-Cu alloy product is AA 2099. Examples of Al-Mg alloy products include any of the AA 5xxx series alloys. In one example, the Al-Mg alloy product is AA 5083. Examples of Al-Mg-Si alloy products include any of the AA 6xxx series alloys. In one example, the Al-Mg-Si alloy product is AA 6013. Examples of Al-Zn/Cu alloy products include any of the AA 7xxx series alloys, including Al-Zn, Al-Zn-Cu, Al-Zn-Mg, or Al-Zn- Cu-Mg, among other similar alloys. In some examples, the Al-Zn/Cu alloy product is AA 7085, AA 7040 and AA 7140.
  • the Al-Mg weld filler alloy or the Al-Mg-Zn weld filler alloy is used to repair an existing aluminum alloy product, such as an Al-Mg or Al-Mg-Si alloy product, among others.
  • the Al-Mg weld filler alloy or the Al-Mg-Zn weld filler alloy is used for forming a weldment joining at least two aluminum alloy segments.
  • the Al-Mg weld filler alloy or the Al-Mg-Zn weld filler alloy is used for welding two aluminum products together (e.g., two base metal segments).
  • the Al-Mg weld filler alloy or the Al-Mg-Zn weld filler alloy is used for joining at least two base metal segments including the likes of AA 5083 and AA 6013, or AA 6013 and AA 7085, or AA 6013 and AA 6013, or AA 7085 and AA 7085, or AA 2099 and AA 2099, or AA 6013 and AA 2099, among other variations or permutations of the 2xxx, 5xxx, 6xxx and 7xxx series aluminum alloys.
  • Aluminum alloy products containing Al-Cu, Al-Mg, Al-Mg-Si and Al-Zn/Cu have predominant amount of at least one Al-Cu alloy, one Al-Mg alloy, one Al-Mg-Si alloy, and one Al-Zn/Cu alloy, respectively.
  • the aluminum alloy products may be wrought products (e.g., rolled products, extrusions, forgings) or cast products (e.g., castings).
  • an aluminum alloy product to be joined or repaired may be a mold plate product.
  • a mold plate is a plate that is used for injection mold parts.
  • the aluminum alloy products to be repaired or joined may include base metal segments, sections, and parts, among others.
  • Use of the disclosed Al-Mg weld filler alloy or Al-Mg-Zn weld filler alloy may facilitate repairing or joining of the aluminum alloy products by improving, for example, one or more of appearance and/or functionality of the repaired or joined portion of the aluminum alloy product, as described in further detail below.
  • the Al-Mg weld filler alloys of the instant application are those alloys containing a predominant amount of at least one Al-Mg alloy.
  • the Al-Mg-Zn weld filler alloys of the instant application are those alloys containing a predominant amount of at least one Al-Mg- Zn alloy.
  • a weld filler alloy is an alloy that is used to repair an aluminum alloy product.
  • a weld filler alloy is an alloy that is used to join base metal segments together.
  • the weld filler alloys may be in the form of rods, wires, and powders that can be clad over a repair area (e.g., with the aid of a laser beam welding process). Other weld filler alloy forms may also be utilized.
  • weld filler wires or rods may be used for repairing a defective weld or a defective aluminum alloy product or base metal.
  • Al-Mg alloys are aluminum alloys comprising magnesium as a primary alloying constituent.
  • Al-Mg-Zn alloys are aluminum alloys comprising magnesium and zinc as primary alloy constituents.
  • the Al-Mg and Al-Mg-Zn weld filler alloys disclosed herein have achieved comparable (or even better) welding characteristics than that of AA 5083 and AA 5183.
  • the Al-Mg and Al-Mg-Zn weld filler alloys have better weldability than AA 5083 and AA 5183 weld filler alloys for welding 2xxx, 5xxx, 6xxx and 7xxx series aluminum alloys to each other, and to themselves.
  • the Al- Mg and Al-Mg-Zn weld filler alloys have achieved comparable (or even better) appearance characteristics (e.g., color match, cracking, texture), among other properties, than AA 5083 and AA 5183.
  • the Al-Mg and Al-Mg-Zn weld filler alloys disclosed herein have achieved comparable (or even better) functional characteristics (e.g., shear strength, longitudinal tensile strength, transverse tensile strength, elongation, abrasion resistance, durability, shock resistance, wear resistance, pitting adhesion, porosity, hardness, thermal shock, impact resistance), among others, than that of AA 4043 weld filler alloy.
  • Al-Mg weld filler alloy and Al-Mg-Zn weld filler alloy may have better mechanical properties than AA 4043 for welding 2xxx, 5xxx, 6xxx and 7xxx series aluminum alloys to each other, and to themselves.
  • AA 4043 may have similar weldability as the Al-Mg weld filler alloy or the Al-Mg-Zn weld filler alloy disclosed herein.
  • AA 4043 may have similar weldability as the Al-Mg weld filler alloy or the Al-Mg-
  • AA 4043 cannot achieve the mechanical properties, among other properties, of an Al-Mg weld filler alloy or an Al-Mg-Zn weld filler alloy.
  • Aluminum alloys AA 4043, AA 5083 and AA 5183 mean Aluminum Association alloys 4043, 5083 and 5183, respectively, as defined by the Aluminum Association Teal
  • the Al-Mg and Al-Mg-Zn weld filler alloys may also achieve comparable characteristics as described above over other weld filler alloys including AA
  • the Al-Mg and Al-Mg-Zn weld filler alloys disclosed herein may exhibit weldability similar to those of 4xxx series aluminum alloys (e.g., AA
  • AA 5556 and AA 5654 mean Aluminum Association alloys 1100, 2319, 4145, 5354, 5356,
  • Al-Mg and Al-Mg-Zn weld filler alloys useful in accordance with the instant disclosure are disclosed in Table 1 below.
  • Al-Mg-Xl comprises (and in some instances consists essentially of) from about 5.6 wt. % Mg to about 8.0 wt. % Mg, from about 0.01 wt. % to about 0.05 wt. % of a grain refiner, the balance essentially aluminum, incidental elements and impurities.
  • the grain refiner is at least one of Zr, Ti and B, among others.
  • Al-Mg-Xl includes up to about 94.4 wt. % Al.
  • Al-Mg-X2 comprises (and in some instances consists essentially of) from about
  • the grain refiner is at least one of Zr, Ti and B, among others.
  • Al-Mg-X2 includes up to about 94.4 wt. % Al.
  • Al-Mg-X3 comprises (and in some instances consists essentially of) about 5.9 wt.
  • % Mg from about 0.01 wt. % to about 0.05 wt. % of a grain refiner, the balance essentially aluminum, incidental elements and impurities.
  • the grain refiner is at least one of Zr, Ti and B, among others.
  • Al-Mg-X3 includes up to about 94.1 wt. % A1.
  • Al-Mg-Zn-Yl comprises (and in some instances consists essentially of) from about 5.6 wt. % Mg to about 8.0 wt. % Mg, from about 0.05 wt. % Zn to about 3.5 wt. % Zn, from about 0.01 wt. % to about 0.05 wt. % of a grain refiner, the balance essentially aluminum, incidental elements and impurities.
  • the grain refiner is at least one of Zr, Ti and B, among others.
  • Al-Mg-Yl includes up to about 94.4 wt. % Al.
  • Al-Mg-Zn-Y2 comprises (and in some instances consists essentially of) from about 5.6 wt. % Mg to about 6.2 wt. % Mg, from about 1.7 wt. % Zn to about 2.3 wt. % Zn, from about 0.01 wt. % to about 0.05 wt. % of a grain refiner, the balance essentially aluminum, incidental elements and impurities.
  • the grain refiner is at least one of Zr, Ti and B, among others.
  • Al-Mg- Y2 includes up to about 92.7 wt. % Al.
  • Al-Mg-Zn-Y3 comprises (and in some instances consists essentially of) about 5.9 wt. % Mg, about 2.0 wt. % Zn, from about 0.01 wt. % to about 0.05 wt. % of a grain refiner, the balance essentially aluminum, incidental elements and impurities.
  • the grain refiner is at least one of Zr, Ti and B, among others.
  • Al-Mg-Zn-Y3 comprises (and in some instances consists essentially of) about 5.9 wt. % Mg, about 2.0 wt. % Zn, from about 0.01 wt. % to about 0.05 wt. % of a grain refiner, the balance essentially aluminum, incidental elements and impurities.
  • the grain refiner is at least one of Zr, Ti and B, among others.
  • Mg-Y3 includes up to about 92.1 wt. % Al.
  • the Mg content of the weld filler alloy composition may be at least about 5.6 wt. %, or at least about 5.7 wt. %, or at least about 5.8 wt. %, or at least about 5.9 wt. %, or at least about 6.0 wt. %, or at least about 6.1 wt. %, or at least about 6.2 wt. %, or at least about 6.3 wt. %, or at least about 6.4 wt. %, or at least about 6.5 wt. %, or at least about 6.6 wt. %, or at least about 6.7 wt. %, or at least about 6.8 wt.
  • % or at least about 6.9 wt. %, or at least about 7.0 wt. %, or at least about 7.1 wt. %, or at least about 7.2 wt. %, or at least about 7.3 wt. %, or at least about 7.4 wt. %, or at least about 7.5 wt. %, or at least about 7.6 wt. %, or at least about 7.7 wt. %, or at least about 7.8 wt. %, or at least about 7.9 wt. %, or at least about 8.0 wt. %.
  • the Mg content of the weld filler alloy composition may be not greater than about 8.0 wt. %, or not greater than about 7.9 wt. %, or not greater than about 7.8 wt. %, or not greater than about 7.7 wt. %, or not greater than about 7.6 wt. %, or not greater than about 7.5 wt. %, or not greater than about 7.4 wt. %, or not greater than about 7.3 wt. %, or not greater than about 7.2 wt. %, or not greater than about 7.1 wt. %, or not greater than about 7.0 wt. %, or not greater than about 6.9 wt.
  • the Mg content of the weld filler alloy composition may be in the range of from about 5.6 wt. % to about 7.8 wt. %, or from about 5.6 wt. % to about 7.6 wt. %, or from about 5.6 wt. % to about 7.4 wt. %, or from about 5.6 wt. % to about 7.2 wt. %, or from about 5.6 wt. % to about 7.0 wt. %, or from about 5.6 wt. % to about 6.8 wt. %, or from about 5.6 wt. % to about 6.6 wt. %, or from about 5.6 wt.
  • % to about 6.4 wt. % or from about 5.6 wt. % to about 6.2 wt. %, or from about 5.6 wt. % to about 6.0 wt. %, or from about 5.6 wt. % to about 5.9 wt. %, or from about 5.6 wt. % to about 5.8 wt. %, or from about 5.7 wt. % to about 6.0 wt. %, or from about 5.7 wt. % to about 5.9 wt. %, or from about 5.8 wt. % to about 6.0 wt. %, or from about 5.9 wt. % to about 6.0 wt. %, or from about 5.9 wt. % to about 6.0 wt. %, or from about 5.8 wt. % to about 5.9 wt. %, or from about 5.7 wt. % to about 6.1 wt. %.
  • the Zn content of the weld filler alloy composition may be at least about 0.05 wt. %, or at least about 0.1 wt. %, or at least about 0.2 wt. %, or at least about 0.4 wt. %, or at least about 0.6 wt. %, or at least about 0.8 wt. %, or at least about 1.0 wt. %, or at least about 1.2 wt. %, or at least about 1.4 wt. %, or at least about 1.6 wt. %, or at least about 1.8 wt. %, or at least about 2.0 wt. %, or at least about 2.2 wt.
  • the Zn content of the weld filler alloy composition may be not greater than about 3.5 wt. %, or not greater than about 3.4 wt. %, or not greater than about 3.2 wt. %, or not greater than about 3.0 wt. %, or not greater than about 2.8 wt.
  • % or not greater than about 2.6 wt. %, or not greater than about 2.4 wt. %, or not greater than about 2.2 wt. %, or not greater than about 2.0 wt. %, or not greater than about 1.8 wt. %, or not greater than about 1.6 wt. %, or not greater than about 1.4 wt. %, or not greater than about 1.2 wt. %, or not greater than about 1.0 wt. %, or not greater than about 0.8 wt. %, or not greater than about 0.6 wt. %, or not greater than about 0.4 wt. %, or not greater than about 0.2 wt. %, or not greater than about 0.1 wt. %, or not greater than about 0.05 wt. %.
  • the Zn content of the weld filler alloy composition may be in the range of from about 0.5 wt. % to about 3.5 wt. %, or from about 0.5 wt. % to about 3.0 wt. %, or from about 1.0 wt. % to about 3.0 wt. %, or from about 1.5 wt. % to about 3.0 wt. %, or from about 1.5 wt. % to about 2.5 wt. %, or from about 2.0 wt. % to about 2.5 wt.%, or from about 1.7 wt. % to about 2.3 wt. %, or from about 1.8 wt. % to about 2.2 wt. %, or from about 1.9 wt. % to about 2.1 wt. %.
  • the present disclosure provides a weld filler alloy comprising from about 5.6 wt. % Mg to about 8 wt. % Mg, from about 0.05 wt. % Zr to about 0.25 wt. % Zr, and a grain refiner, where the grain refiner includes at least one of titanium boride, titanium carbide, hafnium, scandium or mixtures thereof, and balance aluminum, incidental elements and impurities.
  • the present disclosure provides a weld filler alloy comprising from about 5.6 wt. % Mg to about 8 wt. % Mg, from about 0.05 wt. % Zr to about 0.25 wt.
  • the present disclosure provides a weld filler alloy comprising from about 5.6 wt. % Mg to about 8 wt. % Mg, from about 0.05 wt. % Zn to about 3.5 wt. % Zn, from about 0.05 wt. % Zr to about 0.25 wt.
  • the present disclosure provides a weld filler alloy comprising from about 5.6 wt. % Mg to about 8 wt. % Mg, from about 0.05 wt. % Zn to about 3.5 wt. % Zn, from about 0.05 wt. % Zr to about 0.25 wt. % Zr, from about 0.01 wt. % Ti to about 0.09 wt. % Ti, from about 0.003 wt. % B to about 0.03 wt. % B, and the balance aluminum, incidental elements and impurities.
  • the weld filler alloy is provided in the form of a weld wire or welding rod.
  • fusion zone means the region between the weld filler alloy and the base metal at which the weld filler alloy starts to solidify off the epitaxy of the base metal (e.g., the grains or dendrites at which solidification of the weld starts by providing the surface energy for heterogeneous nucleation of the first dendrites of the solidifying weld).
  • heat affected zone means the area in the base metal located between the fusion zone and the un-affected base metal.
  • the heat affected zones (HAZs) are the areas in the base metals which are affected by the heat used for welding the base metal parts together.
  • the larger the grains are in these regions e.g., HAZ portion adjacent to fusion zone
  • the more likely hot cracking is to occur. This is because larger grains form more continuous grain boundaries along which low melting eutectics can accumulate and form nearly continuous partially molten films, which can result in a higher propensity to tear and open up in the form of hot cracks under stress.
  • the grains in the HAZ adjoining the welds tend to grow and form microstructures which are more conducive to hot cracking.
  • smaller grains may be needed to reduce or prevent hot cracking, which may reduce tearing since partially molten films formed along grain boundaries are not as continuous and connected as larger grains.
  • the Al-Mg and Al-Mg-Zn weld filler alloys disclosed herein may produce small grain sizes and substantially minimize grain growth in the HAZs next to the fusion zone, which may lessen the formation of hot cracking.
  • the solidus temperatures of the weld filler alloy and the various dilution of the base metal into the weld need to be lower than the solidus temperatures of the base metal.
  • the composition of the weld consists mostly of weld filler alloy.
  • the weld may include higher and higher amounts of the base metal material mixed with the weld filler alloy.
  • portions of the weld with different dilution ratios may follow different solidus temperature paths (e.g., different solidification paths) than the weld filler alloy and/or the base metal.
  • solidus temperatures of the various dilution ratios of the base metal into the weld still need to be lower than the solidus temperatures of the base metal across substantially all solid/liquid fractions. This will ensure that the base metal solidifies before the weld filler alloy and also the various dilution ratios thereby reducing the possibility of tearing and cracking within the weld.
  • solidus temperature is the temperature at which a given substance solidifies and/or crystallizes.
  • solidus temperature means the temperature at which an alloy starts to melt upon heating and completes its solidification upon cooling from a melt.
  • a lower solidus temperature means that at any given time and at a fixed temperature, the amount of solidification in a base metal (e.g., 2xxx, 5xxx, 6xxx or 7xxx series aluminum alloy products/segments) will be higher than the amount of solidification in a weld filler alloy (e.g., Al-Mg or Al-Mg-Zn). This means that the partially molten base metal will solidify before the weldment, and be stronger and less prone to cracking.
  • solid/liquid fraction means the solid fraction of a weld (e.g., molten metal) on a mass basis.
  • the solid/liquid fraction gradually increases from a value of 0.00 (e.g., weld is mostly molten metal) to 1.00 (e.g., weld is mostly solid).
  • a solid/liquid fraction of 0.20 means that the weld is about 20% solid with about 80% molten metal (e.g., liquid)
  • a solid/liquid fraction of 0.60 means that the weld is about 60% solid and about 40% molten metal (e.g., liquid).
  • the solidus temperature of the weld filler alloys may be at least about 1 0 C lower than the base metals, or at least about 2 0 C lower, or at least 3 0 C lower, or at least about 4 0 C lower, or at least about 5 0 C lower, or at least about 6 0 C lower, or at least about 7 0 C lower, or at least about 8 0 C lower, or at least about 9 0 C lower, or at least about 10 0 C lower.
  • the solidus temperature trend (e.g., weld filler alloys being lower than the base metals) may be true across all solid/liquid fractions, or at least across a majority of solid/liquid fractions.
  • the weldment containing the Al-Mg or Al- Mg-Zn weld filler alloy may solidify after the partially molten base metal aluminum alloy products/segments thereby leading to a stronger weldment that is less prone to cracking. This will become more apparent in subsequent figures and discussion.
  • the weld filler alloy compositions disclosed herein for melting and mixing with the base metals are able to provide weld deposits whose solidus temperatures are lower than the solidus temperatures of the base metals being joined and/or repaired. This allows the partially molten base metals to solidify in the fusion zone and adjoining HAZs thereby substantially preventing hot cracking and liquation cracking in these regions of the weldments.
  • the weld filler alloy compositions may include T1B 2 and/or Zr as grain refiners to minimize the size of the dendrites and spacing between them in the weld.
  • the addition of grain refiners to the Al-Mg or Al-Mg-Zn weld filler alloy may help minimize the size of dendrites formed and spacing between the dendrites thereby minimizing the propensity for liquation cracking in the welds and regions next to the fusion zones.
  • One of the weld filler alloys includes Zn for improved resistance to sensitization, which in turn reduces propensity to stress corrosion cracking of the weld deposits and further suppresses the solidus temperatures of the solidifying welds, at different solid to liquid fractions.
  • the weld filler alloy has a weight ratio of 3 : 1 of titanium to boron.
  • the weld filler alloy may be provided proximal to the defective area of the part.
  • the defective part and the weld filler alloy may subsequently be melted and/or fused together into a weldment.
  • the weld filler alloy may be in the form of a weld wire or a weld rod, among others.
  • the weld filler alloy has a solidus temperature that is lower than the solidus temperature of the base metal and which upon fusion welding and dilution with the base metal being repaired results in the weldment whose solidus temperature is lower than the solidus temperatures of the base metal being welded, at any solid/liquid fraction during the solidification of the weldment.
  • the weld filler alloy compositions disclosed herein may weld the following combinations of base metals including, but are not limited to, AA 7085 to AA 7085, AA 7085 to AA 6013, AA 7085 to AA 5083, AA 7085 to AA 2099, AA 7085 to modified AA 7085, modified AA 7085 to modified AA 7085, modified AA 7085 to AA 6013, modified AA 7085 to AA 5083, modified AA 7085 to AA 2099, AA 6013 to AA 6013, AA 6013 to AA 5083, AA 6013 to AA 2099, AA 5083 to AA 5083, AA 5083 to AA 2099, and AA 2099 to AA 2099.
  • Some embodiments of AA 7085 and modified AA 7085 base metals capable of being joined or welded in accordance with the instant disclosure are disclosed in Table 2 below.
  • AA 7085-1 base metal includes from about 1.3 wt. % Cu to about 2.0 wt. % Cu, from about 1.2 wt. % Mg to about 1.8 wt. % Mg, from about 7 wt. % Zn to about 8 wt. % Zn, the balance essentially aluminum, incidental elements and impurities.
  • the AA 7085-2 base metal includes about 1.6 wt. % Cu, about 1.5 wt. % Mg, about 7.5 wt. % Zn, the balance essentially aluminum, incidental elements and impurities.
  • modified AA 7085-1 and modified AA 7085-2 base metals include similar compositions as those of AA 7085-1 and AA 7085-2, respectively, with variations in incidental elements and impurities.
  • the alloys of the present disclosure generally include the stated alloying ingredients, the balance being aluminum, optional grain structure control elements, optional incidental elements and impurities.
  • grain structure control element means elements or compounds that are deliberate alloying additions with the goal of forming second phase particles, usually in the solid state, to control solid state grain structure changes during thermal processes, such as recovery and recrystallization.
  • grain structure control elements include Zr, Sc, V, Cr, Mn, and Hf, to name a few.
  • the amount of grain structure control material utilized in an alloy is generally dependent on the type of material utilized for grain structure control and the alloy production process.
  • zirconium (Zr) is included in the alloy, it may be included in an amount up to about 0.4 wt. %, or up to about 0.3 wt. %, or up to about 0.2 wt. %, or up to about 0.1 wt. %.
  • Zr is included in the alloy in an amount of from about 0.05 wt. % to about 0.15 wt. %.
  • Zr is included in the alloy in an amount of from about 0.09 wt. % to about 0.11 wt. %.
  • Scandium (Sc), vanadium (V), chromium (Cr), manganese (Mn) and/or hafnium (Hf) may be included in the alloy as a substitute (in whole or in part) for Zr, and thus may be included in the alloy in the same or similar amounts as Zr.
  • no grain structure control elements are used, such as when there is no inherent need to control, for example, recrystallization.
  • manganese is not added or included in the alloy.
  • incident elements means those elements or materials that may optionally be added to the alloy to assist in the production of the alloy.
  • incidental elements include casting aids, such as grain refiners and deoxidizers.
  • Grain refiners are inoculants or nuclei to seed new grains during solidification of the alloy.
  • An example of a grain refiner is a 3/8 inch rod comprising 96% aluminum, 3% titanium (Ti) and 1% boron (B), where virtually all boron is present as finely dispersed TiB 2 particles.
  • the grain refining rod is fed in-line into the molten alloy flowing into the casting pit at a controlled rate.
  • grain refiner included in the alloy is generally dependent on the type of material utilized for grain refining and the alloy production process.
  • grain refiners include Ti combined with boron (e.g., TiB 2 ) or carbon (TiC), although other grain refiners, such as Al-Ti master alloys may be utilized.
  • grain refiners used in aluminum base metals or weld filler alloys may include, but are not limited to, Hf, Sc, Zr, Y, other lanthanide elements or mixtures thereof.
  • lanthanide elements means any of the chemically related elements with atomic numbers 57 through 71 (i.e., lanthanum, cerium, praseodymium, neodymium, promethium, samarium, europium, gadolinium, terbium, dysprosium, holmium, erbium, thulium, ytterbium, and lutetium).
  • grain refiners e.g., carbon or boron
  • grain refiners may be added to the alloy in an amount of ranging from 0.0003 wt. % to 0.03 wt. %, depending on the desired as-cast grain size.
  • Ti may be separately added to the alloy in an amount up to 0.03 wt. %, or up to about 0.06 wt. %, to increase the effectiveness of grain refiner.
  • Ti When Ti is included in the alloy, it is generally present in an amount of up to about 0.10 or 0.20 wt. %, or from about 0.01 wt. % to about 0.09 wt. %.
  • B is included in the alloy, it is generally in an amount of up to about 0.02 wt.
  • the ratio of Ti to B may be about 3 to 1.
  • Some alloying elements generally referred to herein as deoxidizers (irrespective of whether the actually deoxidize), may be added to the alloy during casting to reduce or restrict (and in some instances eliminate) cracking of the ingot resulting from, for example, oxide fold, pit and oxide patches.
  • deoxidizers include Ca, Sr, and Be. When calcium (Ca) is included in the alloy, it is generally present in an amount of up to about 0.05 wt. %, or up to about 0.03 wt.
  • Ca is included in the alloy in an amount of 0.001 - 0.03 wt. % or about 0.05 wt. %, such as from about 0.001 wt. % to about 0.008 wt. % (or 10 to 80 ppm).
  • Strontium (Sr) may be included in the alloy as a substitute for Ca (in whole or in part), and thus may be included in the alloy in the same or similar amounts as Ca.
  • beryllium (Be) additions have helped to reduce the tendency of ingot cracking, though for environmental, health and safety reasons, some embodiments of the alloy are substantially Be-free.
  • Incidental elements may be present in minor amounts, or may be present in significant amounts, and may add desirable or other characteristics on their own without departing from the alloy described herein, so long as the alloy retains the desirable characteristics described herein. It is to be understood, however, that the scope of this disclosure should not/cannot be avoided through the mere addition of an element or elements in quantities that would not otherwise impact on the combinations of properties desired and attained herein.
  • impurities are those materials that may be present in the alloy in minor amounts due to, for example, the inherent properties of aluminum and/or leaching from contact with manufacturing equipment.
  • Iron (Fe) and silicon (Si) are examples of impurities generally present in aluminum alloys.
  • manganese (Mn) may be an impurity.
  • the Fe content of the alloy should generally not exceed about 0.25 wt. %. In some embodiments, the Fe content of the alloy is not greater than about 0.15 wt. %, or not greater than about 0.10 wt. %, or not greater than about 0.08 wt. %, or not greater than about 0.05 or 0.04 wt. %.
  • the Si content of the alloy should generally not exceed about 0.25 wt. %, and is generally less than the Fe content. In some embodiments, the Si content of the alloy is not greater than about 0.15 wt. %, or not greater than about 0.12 wt. %, or not greater than about 0.10 wt. %, or not greater than about 0.06 wt. %, or not greater than about 0.03 or 0.02 wt. %.
  • the weld filler alloy composition includes not greater than about 0.05 wt. % Mn as impurity. In some embodiments, the weld filler alloy composition includes impurities of less than about 0.4 wt. % Mn, or not greater than about 0.35 wt. % Mn, or not greater than about 0.3 wt. % Mn, or not greater than about 0.25 wt. % Mn, or not greater than about 0.20 wt. % Mn, or not greater than about 0.15 wt. % Mn, or not greater than about 0.10 wt. % Mn. In one embodiment, the weld filler alloy composition disclosed herein is substantially free of Mn. In some embodiments, the weld filler alloy composition disclosed herein need not include any amount of Mn or include minimal amount of Mn that is present as an impurity.
  • manganese may be a reproductive toxin and may cause neurological disorders (e.g., manganism). In other instances, manganese poisoning may be associated with secondary Parkinson's disease. Further, some studies have demonstrated neurological changes (e.g., poor motor function) with exposure to low levels of manganese.
  • occupational exposure limits (OELs) to manganese may be not greater than about 0.05 mg/m total dust level over an 8-hour time weighted average (TWA), or not greater than about 0.02 mg/m 3 respirable dust level over an 8-hour TWA.
  • OELs may be not greater than about 0.2 mg/m 3 total dust level over an 8- hour time weighted average (TWA), or not greater than about 0.2 mg/m 3 inhalable dust level over an 8-hour TWA, or not greater than about 0.02 mg/m 3 respirable dust level over an 8- hour TWA.
  • the manganese exposure may have a ceiling of not greater than about 5 mg/m 3 .
  • welding fumes may arise from a weld filler wire. These fumes may include magnesium in addition to oxides of manganese.
  • the OELs for the oxides of manganese may be not greater than about 10 mg/m total inhalable dust level over an 8-hour TWA, or not greater than about 15 mg/m 3 total inhalable dust level over an 8-hour TWA.
  • exposure to magnesium oxide fumes may cause metal fume fever, which is a fever-like condition that may be reversed upon removal from such exposure.
  • each of the first aluminum product and the second aluminum product is at least one of 2xxx, 5xxx, 6xxx and 7xxx series aluminum alloy.
  • the two aluminum products may be placed proximal to each other to facilitate the welding process.
  • the welding step may include welding the 2xxx, 5xxx, 6xxx and 7xxx series aluminum alloy products to each other (e.g., 6xxx to 5xxx, 2xxx to 7xxx) or to itself (e.g., 7xxx to 7xxx, 6xxx to 6xxx) using an Al-Mg weld filler alloy or an Al-Mg-Zn weld filler alloy to produce a welded aluminum alloy product.
  • the weld filler alloy utilized may include any of the compositions disclosed herein.
  • welding means to join at least two aluminum parts together by at least one of heating, melting, fusing, or combinations thereof, with the assistance of a weld filler alloy.
  • welding processes include gas tungsten arc welding (GTAW), shielded metal arc welding (SMAW), gas metal arc welding (GMAW), plasma arc welding (PAW), plasma welding (PW), electron beam welding (EBW), and laser beam welding (LBW), to name a few.
  • Suitable types of welding joints for welding base metals with the weld filler alloys include but are not limited to, lap-fillet, square-type butt, vee-type butt, and tee-fillet, among others.
  • 2xxx, 5xxx, 6xxx and 7xxx series aluminum alloy products may be welded together, whether to each other or to itself, by patch welding.
  • Patch welding is welding in a localized area for the purpose of repair of a damages area (e.g., crack(s), worn down areas), and which has the appearance of a patch.
  • welding involves melting and/or fusing the two aluminum products and the weld filler alloy to form a weldment.
  • the weld filler alloy utilized may include any of the compositions disclosed herein.
  • the two aluminum base metal segments may be placed proximal to each other. Subsequently, welding of the two aluminum base metal segments and the weld filler alloy may be carried out by melting and/or fusing the base metal segments and the weld filler alloy into a weldment.
  • both the Al-Mg and the Al-Mg-Zn weld filler alloys have lower solidus temperatures than the 2xxx, 5xxx, 6xxx and 7xxx aluminum alloy products.
  • a method includes welding at least one 2xxx, 5xxx, 6xxx or 7xxx aluminum alloy product to another 2xxx, 5xxx, 6xxx or 7xxx aluminum alloy product with an Al-Mg or Al-Mg-Zn weld filler alloy, where the 2xxx, 5xxx, 6xxx and 7xxx aluminum alloy products have higher solidus temperatures than the Al-Mg or Al-Mg-Zn weld filler alloys.
  • segments of 2xxx, 5xxx, 6xxx or 7xxx series aluminum alloys may be welded to each other or to itself.
  • a first aluminum alloy segment may be welded or joined to a second aluminum alloy segment via a weldment, where the weldment includes a weld filler alloy, and where each of the first aluminum alloy segment and the second aluminum alloy segment is at least one of 2xxx, 5xxx, 6xxx and 7xxx series aluminum alloy.
  • the weld filler alloy includes the weld filler alloy compositions disclosed herein.
  • the segments may be welded and/or repaired in accordance with the techniques and methods disclosed herein.
  • the 2xxx, 5xxx, 6xxx or 7xxx series aluminum alloy products may be welded and/or repaired with the weld filler alloys disclosed herein.
  • the welded and/or repaired aluminum alloy products may have improved conditions due to a welding and/or repairing step.
  • a 2xxx, 5xxx, 6xxx or 7xxx series aluminum alloy mold plate product may be welded and/or repaired by welding an Al- Mg or Al-Mg-Zn weld filler alloy to the mold plate product. Since the product is welded and/or repaired, it may realize an improved condition, and thus, in some instances, may be restored so that it may perform at least one of its original intended functions.
  • the welded and/or repaired 2xxx, 5xxx, 6xxx or 7xxx series aluminum alloy product comprises an original portion, a repaired portion, or an additional portion.
  • the welded and/or repaired portion may have a substantially similar appearance as the original portion.
  • the appearance relates to color.
  • the welded and/or repaired portion has substantially the same color as the original portion.
  • a welded and/or repaired portion is substantially the same color when, as viewed with the naked eye, it appears to have the same color as that of the original portion of the product, when viewed with 20/20 vision and lighting conditions comparable to normal, sunny outdoor lighting.
  • the welded and/or repaired portion has substantially the same texture as the original portion.
  • a welded and/or repaired portion has substantially the same texture as the original portion when the grain size and orientation of the welded and/or repaired portion closely replicates that of the original grain portion (e.g., as traced to a master plaque).
  • An original portion of the 2xxx, 5xxx, 6xxx or 7xxx series aluminum alloy product is a portion of a product that was a part of the product before a welding and/or repairing step.
  • a welded and/or repaired portion of the 2xxx, 5xxx, 6xxx or 7xxx series aluminum alloy product is a portion of a product that was not a part of the product before a welding and/or repairing step, but constitutes a part of the product (e.g., an integral part of the product) after the welding and/or repairing step (e.g., a weld-deposit or weldment).
  • a mold plate may comprise an original portion and one or more defects.
  • a mold plate may comprise an original portion and at least one repaired portion, which portion may be integral with the product.
  • a mold plate may comprise an original portion of one aluminum alloy and at least an additional portion which contains the same aluminum alloy or a different aluminum alloy.
  • An integral portion means that the welded and/or repaired area has become integrated with the 2xxx, 5xxx, 6xxx or 7xxx series aluminum alloy product.
  • the integrated portion at least partially assists in restoring the appearance (e.g., cracking, color match, texture) and/or functionality (e.g., shock resistance, wear resistance) of the 2xxx, 5xxx, 6xxx or 7xxx series aluminum alloy product that is welded and/or repaired.
  • appearance e.g., cracking, color match, texture
  • functionality e.g., shock resistance, wear resistance
  • the weldments of the 2xxx, 5xxx, 6xxx or 7xxx series aluminum alloy products/segments are substantially free of cracks.
  • a weldment is substantially free of cracks when it contains no greater than the amount of cracks a similarly welded and/or repaired weldment produced from the AA 5083, AA 5183, AA 5356, AA 5556 or AA 4145 weld filler alloys contain.
  • the welded portion and/or repaired product contains at least about 10% fewer cracks than a similarly welded and/or repaired portion produced from AA 5083, AA 5183, AA 5356, AA 5556 or AA 4145 weld filler alloys.
  • the welded and/or repaired portion may contain at least about 15% fewer, or at least about 20% fewer, or at least about 25% fewer, or at least about 30% fewer, or at least about 35% fewer, or at least about 40% fewer, or at least about 45% fewer, or at least about 50% fewer, or at least about 60% fewer, or at least about 70% fewer cracks than a similarly welded and/or repaired portion produced from AA 5083, AA 5183, AA 5356, AA 5556 or AA 4145 weld filler alloys, among others.
  • the welded and/or repaired portion may contain crack lengths that are not greater than about 0.01 mm, or not greater than about 0.02 mm, or not greater than about 0.03 mm, or not greater than about 0.04 mm, or not greater than about 0.05 mm, or not greater than about 0.06 mm, or not greater than about 0.07 mm, or not greater than about 0.08 mm, or not greater than about 0.09 mm, or not greater than about 0.1 mm, or not greater than about 0.12 mm, or not greater than about 0.15 mm, or not greater than about 0.2 mm, or not greater than about 0.25 mm, or not greater than about 0.3 mm, or not greater than about 0.4 mm, or not greater than about 0.5 mm, or not greater than about 1 mm, or not greater than about 2 mm, or not greater than about 5 mm, or not greater than about 10 mm, than a similarly welded and/or repaired portion produced from AA 5083, AA 5183, AA 53
  • a similarly welded and/or repaired portion means that similar welding procedures are used to prepare a weldment, excluding the choice of the type of weld filler alloy.
  • a crack is an internal or external surface opening and/or discontinuity.
  • a crack generally affects the performance (e.g., shock resistance, wear resistance) of the original 2xxx, 5xxx, 6xxx or 7xxx series aluminum alloy products/segments.
  • the welded portion and/or repaired product/segments is at least as durable as a similarly welded and/or repaired portion produced from AA 5083, AA 5183, AA 5356, AA 5556 or AA 4145 weld filler alloys, among others.
  • welded and/or repaired 2xxx, 5xxx, 6xxx or 7xxx series aluminum alloy products/segments using the Al-Mg or Al-Mg-Zn weld filler alloys disclosed herein may be at least as durable as (or more durable than) the same aluminum alloy products/segments welded and/or repaired using AA 5083, AA 5183, AA 5356, AA 5556 or AA 4145 weld filler alloys, among others.
  • the welded and/or repaired aluminum alloy products/segments using the Al- Mg or Al-Mg-Zn weld filler alloys may achieve at least the same amount of acceptable injection shots (or within acceptable statistical deviation) as that of the same aluminum alloy products/segments welded and/or repaired using AA 5083, AA 5183, AA 5356, AA 5556 or AA 4145 weld filler alloys, among others.
  • Acceptable injection shots are those shots in which the products/segments produce aluminum products having acceptable texture and color match.
  • the welded portion and/or repaired product is at least twice as durable as a similarly welded and/or repaired portion produced from AA 5083, AA 5183, AA 5356, AA 5556 or AA 4145 weld filler alloys, among others.
  • the welded portion and/or repaired product may demonstrate little or reduced (and none in some instances) pitting.
  • Pitting means a discontinuity not greater than about 1 mm in diameter and/or depth. In other embodiments, pitting may not be greater than about 2 mm, or not greater than about 5 mm, or not greater than about 0.5 mm, or not greater than about 0.1 mm. Pitting can result from a poor weld and leave voids that have a detrimental impact on the surface to be textured in the instance of mold plates.
  • the welded and/or repaired portion is adherent.
  • Adherent means that the weld-deposit (e.g., weldment), which is used to weld and/or repair the damaged area of the 2xxx, 5xxx, 6xxx or 7xxx series aluminum alloy products/segments, reliably continues to adhere to the welded and/or repaired portion in service (e.g., repeatable injection-molding shots), while continuing to retain/provide at least some of the appearance and/or functional properties discussed herein (e.g., wear resistance, cracking, texture, color match, shock resistance).
  • weld-deposit e.g., weldment
  • the welded portion and/or repaired product may be wear resistant.
  • Wear resistant means that the hardness of the weld-deposit (e.g., weldment), which is used to weld and/or repair the damaged area of the 2xxx, 5xxx, 6xxx or 7xxx series aluminum alloy products/segments, will provide wear resistance necessary to withstand repeated and numerous injection-molding shots in service.
  • the hardness of this weld-deposit may be chosen so it is compatible with the hardness of the original portion of the 2xxx, 5xxx, 6xxx or 7xxx series aluminum alloy products/segments.
  • the welded portion, and sometime the whole repaired 2xxx, 5xxx, 6xxx or 7xxx series aluminum alloy products/segments may be artificially aged (e.g., to an appropriate temper) after the repairing step to facilitate production of a welded and/or repaired portions which has a hardness and/or wear resistance that resembles that of the original portion.
  • the welded portion and/or repaired product has a hardness that is at least equivalent to that of a welded and/or repaired portion produced from AA 5083, AA 5183, AA 5356, AA 5556 or AA 4145 weld filler alloys, among others.
  • the welded portion and/or repaired product may be thermal shock resistant.
  • Thermal shock resistant means that the weld-deposit (e.g., weldment), which is used to weld and/or repair the 2xxx, 5xxx, 6xxx or 7xxx series aluminum alloy products/segments, and the original portion is able to withstand repeated and numerous extreme changes in temperature without cracking and/or to a degree that adversely affects the performance of the weldment.
  • the welded portion and/or repaired product may be impact shock resistant.
  • Impact shock resistant means that the weld-deposit (e.g., weldment), which is used to weld and/or repair the 2xxx, 5xxx, 6xxx or 7xxx series aluminum alloy products/segments, and the original portion is able to withstand repeated and numerous mechanical-type impacts without cracking and/or to a degree that adversely affects the performance of the weldment.
  • the weld filler alloys having solidus temperatures that are higher than the base metal segments at certain solid/liquid fractions may have issues repairing or joining base metal segments because the weld filler alloys in the weld deposits may solidify before the base metal segments thereby leading to cracking within the weld.
  • the repair when repairing a base metal plate, the repair can take place by welding the base metal plate via a weld filler alloy to produce a repaired base metal plate.
  • the weld filler alloy can be an Al-Mg alloy or an Al-Mg-Zn alloy.
  • the base metal plate can be any aluminum alloy of the 2xxx, 5xxx, 6xxx or 7xxx series. And the weld filler alloy can have substantially lower solidus temperatures than the base metal plate at all solid/liquid fractions.
  • the repaired base metal plate can be textured to produce a first object having substantially similar color match as a second object, wherein the second object is produced from a non-repaired base metal plate.
  • an object includes plastic mold of a toy manufactured from a base metal plate including polypropylene injection molding.
  • the color around the weld area is substantially similar such that one cannot tell the difference between an object produced by a repaired base metal plate from another object produced by a non-repaired base metal plate.
  • the levels of weld discontinuities (e.g., cracks and pores) in the weld-repaired deposits should be acceptable to specific applications and conditions encountered in service.
  • Some of the characteristics include without limitation relatively high abrasion resistance, thermal and mechanical shock resistance, and material strength at elevated temperatures. Other characteristics include overall appearance, color match, pitting, adhesion and hardness.
  • the smoothness of the weld-repaired areas allows for ease of blending with adjoining surfaces of the base metal plate.
  • chemical compatibility of the weld-repaired deposits with an aluminum alloy base metal plate may be enhanced after texturing by chemical etching.
  • texturing is carried out in order to restore a base metal plate to its original texture, or as close to it as possible.
  • the attempt to restore the base metal plate to its original texture may be necessary for control over the surfaces of the injection parts and preventing them from sticking to the base metal plates during injection molding processes and the removal of the parts.
  • restoring a base metal plate to its original texture or having the fusion welding repair to be as close to the original texture as possible is critical to the object or plastic part produced.
  • One of the characteristics of judging chemical compatibility is the degree of discoloration imparted to the plastic parts upon their removal from the repaired base metal plate.
  • the discoloration of the parts may be caused by variations in the textured weld- repaired areas (e.g., the way the areas are etched compared to the original aluminum alloy base metal plate), which can lead to visible changes to the way light is reflected and absorbed by the plastic parts and/or actual leaching of aluminum alloy(s) from the weld deposits into the plastic parts.
  • the weld-repaired area should cause no such discoloration to the production application products or parts.
  • the repair technique of a base metal plate with an Al-Mg or Al-Mg-Zn weld filler alloy may include: a) removing an affected (damaged, e.g.
  • the quality and characteristics of the areas weld-repaired with the weld filler alloy and/or weld-repair techniques as previously described may be checked against injection molded plastic coupons that are produced of the plastic material of interest (e.g., polyethylene and polypropylene) with the injection molding conditions (e.g., texture of mold, injection mold's temperature and injection molding pressure) and having the desired surface characteristics (appearance, texture, uniformity of color and/or luster). These coupons are used as the "standard" against which the coupons produced after the weld-repair in question.
  • the plastic material of interest e.g., polyethylene and polypropylene
  • injection molding conditions e.g., texture of mold, injection mold's temperature and injection molding pressure
  • desired surface characteristics e.g., texture of mold, injection mold's temperature and injection molding pressure
  • the attributes that are compared include: a) general coupon appearance, b) texture and uniformity across the coupon (e.g., presence of dents), c) uniformity of color (color-match and if there is not a good color-match between the "standard” and sample coupons and/or the surfaces of the sample coupon corresponding to the repaired areas and their adjacent unaffected mold surfaces) or luster, especially between the repaired area and its adjoining unaffected surfaces of the mold plate.
  • FIG. 1 illustrates a comparison of solidus temperatures between an AA 7085 aluminum alloy base metal and welds produced with an AA 5356 weld filler alloy at different solid/liquid fractions, with varying percentage of dilution of the AA 7085 base metal and the AA 5356 weld filler alloy within a weldment (e.g., weld deposit).
  • a 25% dilution means a weld deposit includes about 25% base metal mixed with about 75% weld filler alloy, a 50% dilution means that half of the weld contains base metal and the other half contains weld filler alloy, and a 75% dilution means that about 75% of the base metal is mixed with about 25% of the weld filler alloy in the weld.
  • the various lines represent the different solidification paths that may be taken by a weld deposit as temperature decreases.
  • the line “7085” is representative of the solidification path of the AA 7085 aluminum alloy base metal
  • the line “5356” is representative of the solidification path of the AA 5356 weld filler alloy
  • the three different dilution ratios are representative, respectively, of the solidification paths of the three different dilution ratios within the weld deposit.
  • temperature decreases e.g., solidification and cooling
  • the solid contents within a weld deposit increases.
  • the solid/liquid fraction generally increases for any given solidification path.
  • the amount of solidification (e.g., amount of solid contents) within the base metal is substantially similar to the amount of solidification within the weld filler alloy (e.g., AA 5356). That is, the two have substantially similar solidification paths. Same may be said for the various dilution ratios (e.g., the amount of solidification of the base metal being substantially similar to that of the various dilution ratios).
  • the amount of solidification in the weld filler alloy is substantially similar and sometimes exceeds that of the base metal (e.g., intersect/crossover at about 525 0 C and a solid/liquid fraction of about 0.90).
  • the amount of solidification in both the base metal and the weld filler alloy is substantially similar as both materials slowly increase from having about 20% solid content at about 625 0 C, to having about 70% solid content at about 600 0 C, and eventually to having about 80% solid content at about 575 0 C.
  • Both materials contain about 90% of solid content (e.g., solid/liquid fraction of about 0.90) at a temperature of about 525 0 C.
  • the amount of solidification in the weld filler alloy may exceed those of the base metal (e.g., at solid/liquid fractions of about 0.90 to about 0.95). This may lead to cracking in the fusion zone as discussed above due to tearing of the weld as more weld filler alloy is solidifying before the base metal.
  • Similar trends may be observed for weld filler alloys AA 5183 (FIG. 2) and AA 5556 (FIG. 3), where the solidus temperatures of the weld filler alloys (e.g., AA 5183 and AA 5556) are generally similar or lower than the AA 7085 aluminum alloy base metal and at various dilution ratios. However, at higher solid/liquid fractions, intersection and/or crossover of the solidus temperatures may lead to tearing of the welds as the weld filler alloy solidifies before the base metal.
  • FIGS. 4-5 illustrate solidus temperatures of AA 4043 and AA 4145 weld filler alloys, respectively, versus AA 7085 aluminum alloy base metal at different solid/liquid fractions, with varying percentages of dilution of the AA 7085 base metal and the respective weld filler alloys into the weld-deposit similar to that described above. The effects are more prominent for the 4xxx series aluminum alloys than the 5xxx series aluminum alloys described above.
  • the AA 4043 weld filler alloy As shown in FIG. 4, as a weld deposit is solidifying, the AA 4043 weld filler alloy has the tendency to solidify before the AA 7085 base metal, and also the various dilution ratios at relatively high temperatures and low solid/liquid fractions. However, as the weld deposit continues to cool to about 575 0 C, the AA 4043 weld filler alloy suddenly solidifies from being 60% solid to about 100% solid (e.g., the flat line portion of the 4043 line).
  • the weld deposit may start to exhibit cracking due to more are more of the AA 4043 weld filler alloy solidifying (e.g., about 100% solid content) before the AA 7085 base metal (e.g., about 80% solid content), and beyond from about 85% solid/liquid fractions where the solidus temperatures of the various dilution ratios exceed that of the AA 7085 base metal.
  • AA 4043 weld filler alloy solidifying (e.g., about 100% solid content) before the AA 7085 base metal (e.g., about 80% solid content), and beyond from about 85% solid/liquid fractions where the solidus temperatures of the various dilution ratios exceed that of the AA 7085 base metal.
  • the AA 4145 weld filler alloy exhibits similar trends as that of the AA 4043 weld filler alloy where the intersection and cross-over of the AA 4145 weld filler alloy and various dilution ratios with respect to the AA 7085 base metal occur at about 90% solid content and temperatures of not greater than about 525 0 C.
  • FIG. 6 illustrates a comparison of solidus temperatures between an AA 7085 aluminum alloy base metal and welds produced with an Al-Mg weld filler alloy according to one embodiment of the present disclosure at different solid/liquid fractions, with varying percentage of dilution of the AA 7085 base metal and the Al-Mg weld filler alloy within a weldment (e.g., weld deposit).
  • the Al-Mg weld filler alloy contains about 6% Mg and up to about 94% Al.
  • the solid content in the base metal is generally higher than the solid content in the weld filler alloy (e.g., Al-Mg) at all solid/liquid fractions.
  • the Al-Mg weld filler alloy is about 60% solid while the AA 7085 base metal is about 70% solid.
  • the Al-Mg weld filler alloy is about 85% solid while the AA 7085 base metal is about 90% solid.
  • the Al-Mg weld filler alloy is about 90% solid while the AA 7085 base metal is about 92% solid.
  • the solidus temperatures of a weld deposit having an Al-Mg weld filler alloy according to one embodiment of the present disclosure are unexpectedly surprising and consistently lower than those of the AA 7085 base metal, at all solid/liquid fractions.
  • the Al-Mg weld filler alloy according to one embodiment of the present disclosure is capable of producing substantially crack- free welds for joining base metal segments and/or repairing the same.
  • the solidus temperatures of the various dilution ratios are all lower than the AA 7085 base metal.
  • the Al-Mg weld filler alloy is capable of producing weld deposits with solidus temperatures that are lower than the solidus temperatures of the AA 7085 base metal as various amounts of the AA 7085 base metal are diluted into the weld deposits (e.g., at any base metal/filler alloy dilution ratios).
  • the Al-Mg weld filler alloy upon melting and mixing with the AA 7085 base metal, is capable of producing weld deposits with lower likelihood of cracking because a greater percentage of the AA 7085 base metal will solidify before the Al-Mg weld filler alloy at any solid/liquid fractions.
  • FIGS. 7A and 7B show etched and anodized cross-sectional micrographs, respectively, of a weldment produced with an AA 7085 aluminum alloy base metal with reference numeral 110, an AA 5356 aluminum alloy weld filler wire/weld metal with reference numeral 130, and a fusion zone having a combination of the AA 7085 aluminum alloy base metal and the AA 5356 aluminum alloy weld filler wire/weld metal with reference numeral 120.
  • the cross-sectional views are of a weld produced by gas tungsten arc welding (GTAW) of an end-constrained tee-fillet type joint.
  • GTAW gas tungsten arc welding
  • FIG. 7A shows a photomicrograph at 200 times magnification of an etched cross-section of a weld produced with the AA 7085 aluminum alloy base metal and the AA 5356 aluminum alloy weld filler wire.
  • FIG. 7B shows a photomicrograph at 500 times magnification of an anodized cross-section of a weld produced with the AA 7085 aluminum alloy base metal and the AA 5356 aluminum alloy weld filler wire.
  • a plurality of hot cracks 125 may be seen at the fusion zone 120 and at the grain boundaries in the AA 7085 aluminum alloy base metal.
  • the grains in the AA 7085 aluminum alloy base metal 110 are much larger than the grains of the fusion zone 120 and the weld metal 130.
  • FIGS. 8A and 8B show etched and anodized cross-sectional micrographs, respectively, of a weldment produced with a modified AA 7085 aluminum alloy base metal with reference numeral 210, an Al-Mg weld filler wire/weld metal according to one embodiment of the present disclosure with reference numeral 230, and a fusion zone having a combination of the modified AA 7085 aluminum alloy base metal and the Al-Mg weld filler wire/weld metal with reference numeral 220.
  • the cross-sectional views are of a weld produced by gas tungsten arc welding (GTAW) of an end-constrained tee-fillet type joint.
  • GTAW gas tungsten arc welding
  • FIG. 8A shows a photomicrograph at 200 times magnification of an etched cross-section of a weld produced with the modified AA 7085 aluminum alloy base metal and the Al-Mg weld filler wire.
  • FIG. 8B shows a photomicrograph at 500 times magnification of an anodized cross-section of a weld produced with the modified 7085 aluminum alloy base metal and the Al-Mg weld filler wire.
  • FIG. 8A no hot cracks are visible at the fusion zone 220 or at the grain boundaries in the modified 7085 aluminum alloy base metal 210.
  • the grains in the modified 7085 aluminum alloy base metal 210 are about the same size as the grains in the fusion zone 220 and in the weld metal 230.
  • FIG. 9 shows a photograph of a weldment produced by GTAW two half-inch thick AA 7085 aluminum alloy plates with an AA 5356 aluminum weld filler wire through an end-constrained double tee-fillet joint. This weldment is subsequently inspected with a dye penetrant test, which reveals a plurality of open weld cracks 310 and open surface cracks 320 in the AA 7085 aluminum alloy plates and the weldment further confirming the weld cross- sections of FIGS. 7A and 7B.
  • FIG. 10 shows a photograph of a weldment produced by GTAW two half-inch thick modified AA 7085 aluminum alloy plates with an Al-Mg aluminum weld filler wire according to one embodiment of the present disclosure through an end-constrained double tee-fillet joint.
  • This weldment is subsequently inspected with a dye penetrant test, which reveals substantially no open weld cracks and/or open surface cracks in the modified AA 7085 aluminum alloy plates and the weldment further confirming the weld cross-sections of FIGS. 8A and 8B.
  • FIG. 11 shows a cross-sectional macrograph through a weldment produced with an AA 7085 aluminum alloy base metal and an Al-Mg weld filler wire in accordance with one embodiment of the present disclosure. In this instance, some cracking may be observed around the weldment.
  • FIG. 12 shows a cross-sectional macrograph through a weldment produced with a modified AA 7085 aluminum alloy base metal and an Al-Mg weld filler wire in accordance with one embodiment of the present disclosure. In this instance, very little cracking may be observed around the weldment.
  • ALUMINUM ASSOCIATION 6xxx AND 5xxx SERIES ALUMINUM ALLOYS Fusion welding of AA 6013 aluminum alloy base metal to itself or to AA 5083 aluminum alloy base metal with AA 4043 and AA 4047 aluminum weld filler alloys may be problematic because the welds (e.g., weld deposits) produced with these weld filler alloys may be relatively weak (e.g., low shear and tensile strengths). In addition, the silicon content in these weld filler alloys may form fine, isolated (e.g., non-continuous) and brittle inter- metallic Mg 2 Si materials at the fusion zones or in the welds adjacent the AA 5083 aluminum alloy base metal.
  • this inter-metallic Mg 2 Si material may adversely affect the structural performance of the welds.
  • FIG. 13 illustrates a comparison of solidus temperatures between an AA 6013 aluminum alloy base metal and a weld produced with an AA 5356 aluminum weld filler alloy at different solid/liquid fractions, with varying percentage of dilution of the AA 6013 aluminum alloy base metal and the AA 5356 aluminum weld filler alloy within the weld.
  • the solidus temperatures of the AA 5356 weld filler alloy, along with various dilution ratios of the AA 6013 aluminum alloy base metal and the AA 5356 weld filler alloy into the weld are generally lower than the AA 6013 aluminum alloy base metal at nearly all solid/liquid fractions.
  • the solidus temperatures of the weld intersect the solidus temperatures of the AA 6013 aluminum alloy base metal (e.g., at solid/liquid fraction of about 0.90 and about 575 0 C).
  • the AA 5356 weld filler alloy may not be suitable for joining or repairing AA 6013 aluminum alloy base metals because at some dilution ratios of the AA 6013 aluminum alloy base metal into the weld (e.g., 60% and 75% dilution ratios), the solidus temperatures of the weld with these dilution ratios may exceed the solidus temperatures of the AA 6013 aluminum alloy base metal thereby leading to tearing and cracking of the weld.
  • FIG. 14 illustrates a comparison of the solidus temperatures between an AA 6013 aluminum alloy base metal and a weld produced with an Al-Mg weld filler alloy according to one embodiment of the present disclosure at different solid/liquid fractions, with varying percentage of dilution of the AA 6013 aluminum alloy base metal and the Al-Mg weld filler alloy within the weld.
  • the solidus temperatures of the Al-Mg weld filler alloy, along with various dilution ratios of the AA 6013 aluminum alloy base metal and the Al-Mg weld filler alloy into the weld are generally lower than the AA 6013 aluminum alloy base metal across substantially all solid/liquid fractions, except a slight overlap for the 75% dilution ratio at higher solid/liquid fractions (e.g., from about 0.90 to about 0.95) and lower temperatures (e.g., from about 575 0 C to about 525 0 C).
  • the Al-Mg weld filler alloy according to one embodiment of the present disclosure is able to produce weld deposits having solidus temperatures that are generally lower than those of the AA 6013 aluminum alloy base metal, and would therefore be a generally acceptable weld filler alloy for welding, joining or repairing AA 6013 aluminum alloy base metal to itself or to AA 5083 aluminum alloy base metal without causing a great amount of cracking and/or tearing at the weld deposits.
  • the Al-Mg weld filler alloy according to one embodiment of the present disclosure is an effective weld filler wire or rod because: (a) the grains in parts (e.g., extrusions, sheet, plates, forgings) made of AA 6013 aluminum alloy do not grow at their HAZs as much as the grains at the HAZs in the AA 7085 aluminum alloy; and (b) the eutectics in AA 6013 aluminum alloy melts along the grain boundaries at a higher temper (e.g., about 510 0 C) than the eutectics in AA 7085 aluminum alloy (e.g., about 476 0 C), with hot-cracking along nearly continuous and connected grain boundaries through partially molten low melting eutectics being not as much of an issue as with AA 7085 aluminum alloy. Consequently, the Al-Mg weld filler alloy according to one embodiment of the present disclosure is capable of producing welds for fusion welding an AA 6013 aluminum alloy base metal to itself
  • FIG. 15 shows a photomicrograph at 500 times magnification of an AA 6013-T6 aluminum alloy base metal 410 welded to an AA 5356 aluminum weld filler wire/weld metal 430 via a fusion zone 420, where the fusion zone 420 includes a combination of the AA 6013-T6 aluminum alloy base metal 410 and the AA 5356 aluminum weld filler wire/weld metal 430.
  • This cross-section is of a weldment 420 produced by manual gas tungsten arc welding (GTAW) with an end constrained tee-fillet type of joint.
  • GTAW manual gas tungsten arc welding
  • the microstructures of the weldment 420 are in general course and rough with relatively large grains.
  • FIG. 16 shows a photomicrograph at 500 times magnification of a weldment produced with the standard 6013-T6 with reference numeral 410, a fusion zone having a combination of the AA 6013-T6 aluminum alloy base metal with an Al-Mg weld filler wire/weld metal according to one embodiment of the present disclosure with reference numeral 420, and the Al-Mg weld filler wire/weld metal with reference numeral 430.
  • This cross-section is of a weldment 420 produced by manual gas tungsten arc welding (GTAW) with an end constrained tee-fillet type of joint.
  • GTAW manual gas tungsten arc welding
  • microstructures of the weldment 420 have more pronounced refinement compared to that of FIG. 15, with generally smaller and finer grain sizes. As discussed above, smaller grains have are not as likely to tear (e.g., crack) when a weld solidifies.
  • FIGS. 17A-17D show photomicrographs at 12 times magnification of two different sets of cross-sectional views of tee-fillet type weldments produced with an AA 6013-T6 aluminum alloy base metal and an AA 5356 weld filler wire. As shown in the figures, cracks 510 may be observed in the AA 6013-T6 base metal in the HAZs next to the fusion zones.
  • FIGS. 18A-18D show photomicrographs at 12 times magnification of two different sets of cross-sectional views of tee-fillet type weldments produced with an AA 6013-T6 aluminum alloy base metal and a modified AA 5356 weld filler wire.
  • the modification includes altering grain refiners including the likes of TiB 2 , among others.
  • the weldment in FIGS. 18A and 18B is substantially free of cracks, cracks 510 may be observed in the AA 6013-T6 base metal in the HAZs next to the fusion zones in FIGS. 18C and l8D.
  • FIGS. 19A-19D show photomicrographs at 12 times magnification of two different sets of cross-sectional views of tee-fillet type weldments produced with an AA 6013-T6 aluminum alloy base metal and an AA 4043 weld filler wire.
  • the weldment in FIGS. 19A and 19B is substantially free of cracks, cracks 510 may be observed in the AA 6013-T6 base metal in the HAZs next to the fusion zones in FIGS. 19C and 19D.
  • the cracks in FIG. 19C are generally shorter and smaller than those of FIGS. 17A-17D and FIGS. 18C-18D.
  • FIGS. 2OA and 2OB show photomicrographs at 12 times magnification of cross- sectional views of a tee-fillet type weldment produced with an AA 6013-T6 aluminum alloy base metal and an Al-Mg weld filler wire according to one embodiment of the present disclosure. As shown, there are no cracks visible in the base metal and/or the weldment.
  • the solidification temperatures of the weld filler alloy are lower than the solidification temperatures of the AA 6013 base metal as the solid/liquid fraction approaches 1.00.
  • FIG. 21 illustrates a comparison of the solidus temperatures between an AA 2099 aluminum alloy base metal and a weld produced with an AA 4043 aluminum weld filler alloy at different solid/liquid fractions, with varying percentage of dilution of the AA 2099 aluminum alloy base metal and the AA 4043 aluminum weld filler alloy within the weld.
  • the AA 4043 weld filler alloy has the tendency to solidify before the AA 2099 base metal and at various dilution ratios (e.g., at relatively high temperatures and low solid/liquid fractions).
  • the weld deposit continues cooling to about 575 0 C, the solid content within the AA 4043 weld filler alloy suddenly jumps from about 60% to about 100% (e.g., the flat line portion of the 4043 line). From this point forward (e.g., temperatures not greater than about 575 0 C), the weld deposit may start to exhibit cracking due to more of the AA 4043 weld filler alloy solidifying (e.g., about 100% solid) than the AA 2099 base metal (e.g., about 80% solid). Furthermore, even the solidus temperatures of the various dilution ratios, beyond about 85% solid/liquid fractions, exceed that of the AA 2099 base metal. This behavior is substantially similar to those of the AA 7085 aluminum alloy base metal from above and suggests that the AA 4043 weld filler alloy may not be a suitable material for the AA 2099 base metal because of possible crack formation.
  • the AA 4145 weld filler alloy exhibits similar trends as that of the AA 4043 weld filler alloy where the intersection and cross-over of the AA 4145 weld filler alloy and the various dilution ratios, with respect to the AA 2099 base metal, occur at about 90% solid/liquid fraction and temperatures of not greater than about 525 0 C.
  • FIG. 23 illustrates a comparison of solidus temperatures between an AA 2099 aluminum alloy base metal and a weld produced with an AA 5356 aluminum weld filler alloy at different solid/liquid fractions, with varying percentage of dilution of the AA 2099 aluminum alloy base metal and the AA 5356 aluminum weld filler alloy within the weld.
  • the solidus temperatures of the AA 5356 weld filler alloy, along with various dilution ratios of the AA 2099 aluminum alloy base metal and the AA 5356 weld filler alloy into a weld are generally lower than the AA 2099 aluminum alloy base metal at nearly all solid/liquid fractions.
  • AA 5356 weld filler alloy may be a suitable welding material for the AA 2099 base metal for the most part, but not at all dilution ratio of the AA 2099 base metal into the weld (e.g., not suitable at about 75% dilution ratio) because of the intersecting solidus temperature.
  • FIG. 24 illustrates a comparison of solidus temperatures between an AA 2099 aluminum alloy base metal and a weld produced with an Al-Mg weld filler alloy according to one embodiment of the present disclosure at different solid/liquid fractions, with varying percentage of dilution of the AA 2099 aluminum alloy base metal and the Al-Mg weld filler alloy within the weld.
  • the solidus temperatures of the Al-Mg weld filler alloy, along with various dilution ratios of the AA 2099 aluminum alloy base metal and the Al-Mg weld filler alloy into a weld are generally lower than the AA 2099 aluminum alloy base metal across substantially all solid/liquid fractions.
  • the Al-Mg weld filler alloy according to one embodiment of the present disclosure is able to produce weld deposits having solidus temperatures that are generally lower than those of the AA 2099 aluminum alloy base metal, and would therefore be a generally acceptable weld filler alloy for welding, joining or repairing AA 2099 aluminum alloy base metal to itself or to other aluminum alloy base metal without severe cracking.
  • the solidus temperatures of an Al-Mg-Zn weld filler alloy according to one embodiment of the present disclosure may be generally lower than those of the AA 2099 aluminum alloy base metal, without any intersection and/or crossover.
  • the Al-Mg-Zn weld filler alloy, according to one embodiment of the present disclosure may be a generally acceptable weld filler alloy for welding, joining or repairing AA 2099 aluminum alloy base metal to itself or to other aluminum alloy base metal without severe cracking.
  • an Al-Mg aluminum weld filler alloy according to one embodiment of the present disclosure is capable of fusion welding a first AA 6013-T6 aluminum alloy base metal to a second AA 6013-T6 aluminum alloy base metal. In one embodiment, an Al-Mg aluminum weld filler alloy according to one embodiment of the present disclosure is capable of fusion welding an AA 6013-T6 aluminum alloy base metal to an AA 5083-H32 aluminum alloy base metal.
  • the Al-Mg and the Al-Mg-Zn weld filler alloys according to the present disclosure are capable of producing weldments with improved tension and transverse shear, with improved percent ductility, and with improved blast resistance, among other properties.
  • the longitudinal tensile strengths of welds produced with an Al-Mg aluminum weld filler alloy may be stronger than the strength of welds produced with AA 4043 weld filler alloys (e.g., 288 MPa v. 198 MPa) and slightly stronger than the strength of welds produced with AA 5184 weld filler alloys (e.g., 288 MPa v. 281 MPa).
  • the yield strengths of welds produced with an Al-Mg aluminum weld filler alloy may be stronger than the strength of welds produced with AA 4043 weld filler alloys (e.g., 152 MPa v. 92 MPa) and comparable to the strength of welds produced with AA 5184 weld filler alloys (e.g., 152 MPa v. 150 MPa).
  • the transverse tensile strengths of the AA 6013-T6 base metal weldments produced with the Al-Mg weld filler alloy may be comparable to those produced with the AA 4043 weld filler alloy.
  • the ductility of the former may be somewhat lower than the latter because welds produced with the Al-Mg weld filler alloys may be more porous.
  • FIG. 26 comprises a plurality of photographs of bend specimens of AA 6013 aluminum alloy base metal welded with an AA 4043 weld filler alloy.
  • the bend specimens may be generated using a wrap-around bend test.
  • the AA 6013 base metals with AA 4043 weld filler wires are capable of achieving a maximum bend radius of about 0.375 inch and a maximum elongation of about 14.29 % before cracking becomes visible at a weldment with a bend radius of about 0.31 inch and an elongation of about 16.78 % (best shown in the inset).
  • FIG. 27 comprises a plurality of photographs of bend specimens of AA 6013 aluminum alloy base metal welded with an Al-Mg weld filler alloy according to one embodiment of the present disclosure.
  • the bend specimens may be generated using a wraparound bend test.
  • the AA 6013 base metals welded with the Al-Mg weld filler wires are capable of achieving a maximum bend radius of at least about 0.18 inch and a maximum elongation of at least about 25.77 % with no visible signs of tearing at a weldment (best shown in the inset).
  • the percent bend-elongation of a butt-type weld of a first AA 6013 aluminum alloy base metal welded to a second AA 6013 aluminum alloy base metal using an Al-Mg weld filler alloy according to one embodiment of the present disclosure may be about two times higher than the percent bend-elongation of a similar weld with the AA 4043 weld filler alloy.
  • mass loss criteria under ASTM G67 standard may demonstrate that a weld produced with AA 6013-T6 parts and an Al-Mg weld filler alloy may exhibit a smaller mass-loss than the AA 6013-T6 base metals and their HAZs upon one week exposure to about 100 0 C.
  • a similar weld between an AA 5083 -H32 part and an AA 6013-T6 part with Al-Mg weld filler alloy may exhibit comparable mass-loss to both the AA 5083-H32 base metal and the 6013-T6 base metal, and their respective HAZs.
  • GTAW gas tungsten arc welding
  • the base metal parts being welded may be about half-inch thick plates with existing 5xxx or 4xxx series weld filler alloys or with an Al-Mg or an Al-Mg-Zn weld filler alloy composition (e.g., in wire or rod form) according to one embodiment of the present disclosure.
  • the plates may first be machined to a required dimension (e.g., about 12 inches long by 8 inches wide and half-inch thick).
  • the parts to be welded are subsequently cleaned with a solvent and dried.
  • a horizontal plate is placed onto a welding table and firmly held down against the table with clamps.
  • the long edge of a vertical plate is placed over the horizontal plate and positioned at its mid- width.
  • the two joint areas to be welded are lightly brushed with a stainless steel brush, cleaned with a solvent and dried.
  • the end-constraining plates are brought to the ends of a T(tee) formed between the two plates and manually tack-welded to the end edges of the horizontal and vertical plates.
  • Manually GMA weld the end-constraining plates to the horizontal and vertical plates by depositing fillet joints between them to complete the assembly of the end-constrained tee joint mockup.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Plasma & Fusion (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Arc Welding In General (AREA)
  • Laser Beam Processing (AREA)

Abstract

L'invention concerne des compositions d'alliage de charge de soudage à l'Al-Mg et à l'Al-Mg-Zn destinées à être utilisées sur des métaux de base soudables par fusion en alliage d'aluminium des séries 7xxx, 6xxx, 5xxx et 2xxx. Les alliages de charge de soudage peuvent être utilisés pour relier un premier segment de métal de base en aluminium à un deuxième segment de métal de base en aluminium, les segments en métal de base étant constitués d'au moins un alliage d'aluminium des séries 7xxx, 6xxx, 5xxx et 2xxx. Les alliages de charge de soudage, en forme de fil ou de barre, peuvent également être utilisés pour réparer une soudure défectueuse.
PCT/US2009/065486 2008-11-24 2009-11-23 Alliages de charge soudables par fusion WO2010060021A1 (fr)

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CN108723596A (zh) * 2018-06-06 2018-11-02 上海交通大学 一种提高铝合金激光焊接头性能的方法

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