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Introduction
In automotive, aviation and electrotechnical industries, as well as in the civil
engineering sector, aluminium is currently
considered to be a material of the future [1].
The development of aluminium applications
is related to advances made in the production
of new aluminium alloys which can reach the
strength of good quality carbon steel while
being about 3 times lighter. As of today,
aluminium alloys find applications in building
engineering (constructing structures) (20%),
manufacturing means of transport (26%),
production of wrappings (20%) and electronics (9%) [2]. In the years to come it will
be possible to observe an increase in demand
for aluminium alloys in sectors characterised
by high innovativeness such as aviation, automotive industry and ship building. Alloys
of the EN AW 5xxx series, characterised
by very good weldability, find many applications in the production of modern means of
transport. Alloy EN AW 5352 is used in the
production of sections of spatial frameworks
and floors in Audi A2 cars, whereas alloy
EN AW 5083 is used in the production of door
dr in. Jolanta Matusiak (PhD Eng.), mgr in. Joanna Wycilik (MSc Eng.) Instytut Spawalnictwa,
Zakad Technologii Zgrzewania i Inynierii rodowiska /Department of Resistance and Friction Welding and Environmental Engineering/
No. 4/2013
and window frame pillars in modern trains ing arc, having a double-pulsed arc, as well
[2]. The use of aluminium alloys for frames as the use of low-energy arc welding methand floors in cars reduces their weight by ods (CMT, ColdArc) for joining sheets made
45% when compared to steel materials [1]. of aluminium alloys holds the key to the imHigh-strength weldable aluminium alloys provement of work conditions [4-7]. Research
applied in modern ship building are those of conducted at Instytut Spawalnictwa also conseries 5xxx (5383, 5059) and 7xxx (7020M) firmed that AC Pulse MIG welding (i.e. MIG
[3]. These alloys are used in the construc- welding with variable polarity current detion of increasingly large ship structures due veloped by the OTC Daihen company and
to economic and environmental reasons as Cold Process applied in devices manufaca50% reduction in weight when compared to tured by the Cloos company) used for joining
similar-sized vessels made of conventional small-thickness elements made of aluminium
alloys makes it possible to limit the emission
materials provides numerous advantages.
Without appropriate joining methods al- of fume and gases into the work environment.
This article analyses the impact of mateuminium alloys will not be used in the production of modern means of transport. The rial and technological conditions of welding
development of new methods of welding aluminium alloys by means of innovative
aluminium and their increasing application in AC Pulse and Cold Process methods on the
various industrial sectors are connected with size of pollution emission [8].
hazards to the work environment and human
body. The years to come will see an increase Tests, laboratory testing station and
in the number of welders exposed to nox- testing methodology
iousness caused by the welding of aluminium
Tests on the emission of fume and gas
alloys. High emission of fume and gases as pollutions generated during welding with
well as the chemical composition of the fume a Cold Process method (S-Pulse CP and
and the toxic effect of aluminium on the hu- AC Pulse variants) were carried out for four
man organism has led to aluminium welding aluminium alloys (EN AW 5251, EN AW
being included in the group of technological 6082, EN AW 2017 A and EN AW 5754).
processes being the subject of research works The aluminium welding tests involved the
in occupational medicine as well as triggers use of a 2 mm thick sheet as well as fillthe development and improvement of welding er metals differing in mechanical propertechnologies. A factor shaping work condi- ties and chemical composition. The alloys
tions and affecting welders
health is mainly the emisTable 1. Material scope for tests of pollution emissions
sion of welding fume conWelding method
Cold Process (S-Pulse CP)/ AC Pulse
taining aluminium (Al2O3),
Thickness
Filler metal
Wire diameter
Base metal
magnesium, manganese and
[mm]
(chemical symbol)
[mm]
zinc oxides as well as silicon
AlMg4.5MnZr
1.2
EN AW 5251
2.0
AlMg5Cr
1.2
dioxide (silica). Implement- (PA2) AlMg2Mn0.3
AlMg4.5MnZr
1.2
EN AW 6082
ing innovative arc welding
2.0
AlSi5
1.2
methods for joining alumin- (PA4) AlSi1MgMn
AlMg4.5MnZr
1.2
EN AW 2017A
ium and its alloys in indus2.0
(PA6) AlCu4MgSi
AlCu6MnZrTi
1.2
trial conditions enables an
AlMg4.5MnZr
1.2
EN AW 5754
increased reduction of pollu2.0
(PA11) AlMg3
AlMg5Cr
1.2
tion. Welding with a pulsat6
No. 4/2013
Alloy designation
Chemical
Numerical
symbol
EN AW 5251
AlMg2Mn0,3
EN AW 6082
AlSi1MgMn
EN AW 2017A
AlCu4MgSi
EN AW 5754
AlMg3
Si
Fe
Cu
Mn
Mg
Cr
Zn
Ti
0.15
0.25
0.1
0.3
0.15
0.2
0.25
0.2
0.15
0.1
0.15
in % (m/m)
0.4
0.7-1.3
0.2-0.8
0.40
0.5
0.5
0.7
0.4
Table 3. Chemical composition and mechanical properties of filler metals used in tests [10]
Alloy
Si
Fe
Cu
Mn
Mg
Cr
Zn
Ti
Rm Rp0.2
designation
[MPa] [MPa]
Chemical symbol
in % (m/m)
Al 5087*)
0.25
0.4
0.1
0.7-1.1 4.5-5.2 0.05-0.25 0.25
0.15
275
125
AlMg4.5MnZr
Al 5356
0.25
0.4
0.1
0.05-0.2 4.5-5.5 0.05-0.2 0.1 0.06-0.2 265
120
AlMg5Cr
Al 2319
< 0.20 < 0.30 5.8-6.8 0.2-0.4 < 0.02 0.1-0.25 0.10 0.1-0.2
240
180
AlCu6MnZrTi
Al 4043
4.6-6.0 0.8
0.3
0.05
0.05
0.1
0.20
165
40
AlSi5
*) Filler metal Al 5087 contains additionally 0.1 0.2 % zirconium
Cold Process
Welding current intensity, [A]
Arc voltage, [V]
Filler metal feeding rate, [m/min]
Welding rate, [mm/min]
AC Pulse
Welding current intensity, [A]
Arc voltage, [V]
Filler metal feeding rate, [m/min]
Welding rate, [mm/min]
54-61
14.8
3.4
420
80
15.8
4.9
830
51-54 75-84
15-18 16-20
3.24.73.6
5.1
420
830
No. 4/2013
4,0
Ep [mg/s]
3,5
3,0
3,60
3,56
3,24
3,07
2,86
2,5
2,40
2,0
2,16
2,14
EN AW 2017
EN AW 5754
1,5
1,0
0,5
0,0
EN AW 5251
EN AW 6082
54 A / 14,8 V
80 A / 15,8 V
Ep [mg/s]
EN AW 6082
3,5
3,56
3,0
2,5
2,0
2,40
1,5
1,58
1,0
0,78
0,5
0,0
AlSi5
AlMg4,5MnZr
54-61 A / 14,8-16,8 V
80 A / 15,8-17,5 V
Ep [mg/s]
EN AW 2017A
3,24
3,0
2,5
2,0
2,16
1,5
1,24
1,0
0,84
0,5
0,0
AlMg4,5MnZr
54-61 A / 14,8-16,8 V
AlCu6MnZrTi
80 A / 15,8-17,5 V
6,0
Ep [mg/s]
EN AW 5251
5,0
4,89
4,0
3,60
3,0
3,07
2,0
2,25
1,0
0,0
AlMg4,5MnZr
AlMg5
54 A / 14,8 V
80 A / 15,8 V
Ep [mg/s]
EN AW 5754
3,5
3,37
3,0
2,86
2,5
2,0
2,35
2,14
1,5
1,0
0,5
0,0
AlMg4,5MnZr
AlMg5
54 A / 14,8 V
80 A / 15,8 V
ENOx [mg/s]
0,014
0,015
0,012
0,010
0,011
0,008
0,006
0,006
0,004
0,002
0,000
0,003
EN AW 5251
0,003
EN AW 6082
54 A / 14,8 V
0,002
0,002
EN AW 2017
0,003
EN AW 5754
80 A / 15,8 V
alloy, whereas the lowest fume emission was determined for the alloy
EN AW 5754. The sizes of fume emission accompanying welding alloys of
6xxx and 2xxx series with the use of the
filler metal grade w gat. AlMg4.5MnZr
were similar (Fig.3).
The grade of a filler metal has asignificant impact on the size of fume
emission during welding aluminium alloys. This tendency was revealed for all
the aluminium alloys tested. Particularly significant differences were observed
while welding alloys EN AW 6082
and EN AW 2017A. In the case of the
alloy 6xxx, the wires AlMg4.5MnZr
and AlSi5 were used; for the filler metal
AlSi5 the size of fume emission within a
tested current range was approximately
2.5 times lower in comparison with that
obtained for the wire AlMg4.5MnZr
(Fig. 4). For welding the alloy 2xxx the
wires AlMg4.5MnZr and AlCu6MnZrTi
were used; for the filler metal
AlCu6MnZrTi the size of fume emission within a tested current range was
also approximately 2.5 times lower in
comparison with that obtained for the
wire AlMg4.5MnZr (Fig. 5). While
welding aluminium alloys of 5xxx series (EN AW 5251 and EN AW 5754)
the selection of the filler metal grade
AlMg4.5MnZr proved convenient as
regards to the size of fume emission
(Fig. 6, 7). For the aforesaid filler metal
the size of fume emission was smaller if
compared to the fume emission generated with the filler metal AlMg5Cr.
The wire grade AlMg5Cr was characterised by higher emission during welding alloys of 5xxx series. A difference in
the chemical composition of the wires
AlMg4.5MnZr and AlMg5Cr is concerned with the content of manganese
and magnesium. According to reference
No. 4/2013
0,018
ENOx [mg/s]
EN AW 5754
0,016
0,016
0,014
0,012
0,010
0,008
0,006
0,004
0,002
0,002
0,000
0,004
0,003
AlMg4,5MnZr
AlMg5
54 A / 14,8 V
80 A / 15,8 V
ENOx [mg/s]
EN AW 6082
0,011
0,010
0,008
0,007
0,006
0,004
0,002
0,000
0,003
0,003
AlMg4,5MnZr
AlSi5
54-61 A / 14,8-16,8 V
80 A / 15,8-17,5 V
ENOx [mg/s]
0,006
EN AW 2017A
0,006
0,005
0,004
0,003
0,002
0,003
0,002
0,002
0,001
0,000
AlMg4,5MnZr
54-61 A / 14,8-16,8 V
AlCu6MnZrTi
80 A / 15,8-17,5 V
11
0,018
ENOx [mg/s]
EN AW 5251
0,016
0,014
0,017
0,015
0,0 12
0,010
0,008
0,006
0,004
0,002
0,004
0,003
0,000
AlMg4,5MnZr
54 A / 14,8 V
AlMg5
80 A / 15,8 V
Ep [mg/s]
AlMg4,5MnZr 1,2 mm
3,5
3,0
2,5
2,0
1,5
54 A
80 A
EN AW 5251
EN AW 6082
EN AW 2017
EN AW 5754
ENOx [mg/s]
AlMg4,5MnZr 1,2 mm
0,014
0,012
0,010
0,008
0,006
0,004
0,002
0,000
54 A
EN AW 5251
EN AW 2017
80 A
EN AW 5754
No. 4/2013
Ep [mg/s]
2,5
2,0
1,79
1,5
1,69
1,41
1,0
0,99
0,77
0,5
0,0
1,16
0,99
EN AW 5251
EN AW 6082
52 A / 15,2 V
EN AW 2017
EN AW 5754
79A / 16,8 V
Ep [mg/s]
1,6
1,69
1,4
EN AW 2017A
1,41
1,2
1,0
0,8
0,72
0,6
0,4
0,32
0,2
0,0
AlMg4,5MnZr
53,4 A / 15,3 V
AlCu6MnZrTi
79,4 A / 16,88 V
13
1,2
Ep [mg/s]
EN AW 6082
1,0
0,99
0,98
0,8
0,77
0,6
0,4
0,27
0,2
0,0
AlMg4,5MnZr
AlSi5
52,4 A / 15,22 V
79,2 A / 16,66V
Ep [mg/s]
EN AW 5251
1,8
1,79
1,6
1,66
1,4
1,2
1,0
0,8
0,99
0,99
0,6
0,4
0,2
0,0
AlMg4,5MnZr
AlMg5
51,6 A / 15,16 V
78,6 A / 16,82 V
Ep [mg/s]
EN AW 5754
2,5
2,55
2,0
1,5
1,0
1,68
1,16
1,04
0,5
0,0
AlMg4,5MnZr
52,2 A / 15,2 V
AlMg5
78,6 A / 16,88 V
No. 4/2013
0,009
ENOx [mg/s]
0,008
0,008
0,007
0,006
0,005
0,007
0,007
0,006
0,006
0,004
0,004
0,003
0,003
0,003
0,002
0,001
0,000
EN AW 5251
EN AW 6082
54 A / 15,28 V
EN AW 2017
EN AW 5754
78,2 A / 16,52 V
ENOx [mg/s]
EN AW 5251
0,016
0,017
0,014
0,012
0,010
0,008
0,006
0,004
0,008
0,006
0,004
0,002
0,000
AlMg4,5MnZr
AlMg5
54 A / 15,28 V
78,2 A / 16,52 V
ENOx [mg/s]
EN AW 6082
0,014
0,015
0,012
0,010
0,008
0,009
0,007
0,006
0,004
0,002
0,000
0,003
AlMg4,5MnZr
52,8 A / 15,32 V
AlSi5
78,8 A / 16,78 V
15
NOx
16
No. 4/2013
3,0
AlMg4,5MnZr 1,2 mm
Ep [mg/s]
2,5
2,0
1,5
1,0
0,5
0,0
52,2
EN AW 5251
75,4
EN AW 2017
EN AW 5754
EN AW 5754
Ep [mg/s]
2,5
2,0
1,5
1,0
0,5
0,0
52,5
AlMg4,5MnZr
ENOx [mg/s]
EN AW 5251
0,014
0,012
0,010
0,008
0,006
0,004
0,002
0,000
54
78,2
AlMg5
17
4,0
3,5
3,60
3,07
3,0
2,5
2,0
1,79
1,5
0,99
1,0
0,5
0,0
0,09
0,30
CMT
0,34
0,43
Cold Arc
50 A
AC-Pulse
S-Pulse-CP
80 A
4,0
3,5
3,56
3,0
2,40
2,5
2,0
1,83
1,5
1,0
0,5
0,0
0,15
0,41
CMT
0,99
0,73
0,77
Cold Arc
AC-Pulse
50 A
S-Pulse-CP
80 A
3,5
3,24
Ep [mg/s]
3,0
2,5
2,16
2,0
1,43
1,5
1,0
0,5
0,0
0,38
0,60
CMT
1,69
1,41
0,79
Cold Arc
50 A
AC-Pulse
S-Pulse-CP
80 A
No. 4/2013
Summary
The objective of the tests described in this
study was to determine a method for welding aluminium alloys which could constitute an advantageous alternative as regards
the protection of work environment and the
reduction of pollution emission. A detailed
comparative analysis of pollution emissions related to the use of various methods
for welding aluminium alloys is presented
in Figure 31. The tests revealed that the use
of the CMT, ColdArc, Cold Process and AC
Pulse methods for welding thin-walled ele2,70
2,07
1,91
1,76
1,98
1,82
CP
CP / EN AW 2017 A / AlMg4,5MnZr / 80 A
3,24
CP / EN AW 6082 / AlMg4,5MnZr / 80 A
3,56
CP / EN AW 5251 / AlMg4,5MnZr / 80 A
3,60
AC-Pulse
CMT
1,69
0,99
ColdArc
1,79
MIG conv.
0,60
0,41
0,30
1,43
1,83
20,70
10
100
Ep [mg/s]
Fig. 31. Dust emission during welding of 5xxx, 6xxx and 2xxx series aluminium
alloys with MIG welding and filler metal grade AlMg4.5MnZr
No. 4/2013
19
20
References
No. 4/2013
Cold Process i AC MIG PULSE stali od- 11. PN-EN ISO 15011-1:2010: Health and
safety in welding and allied processes
pornych na korozj i wybranych stopw
Laboratory method for sampling fume
aluminium na emisj zanieczyszcze oraz
and gases Part 1: Determination of
wasnoci i budow strukturaln zczy.
fume emission rate during arc welding
Instytut Spawalnictwa Research Work no.
and collection of fume for analysis
Ma 36, Gliwice, 2012
9. PN-EN 573-3:2010P Aluminum and alu- 12. PN-EN ISO 15011-4:2008/A1:2009:
Health and safety in welding and allied prominum alloys Chemical composition
cesses Laboratory method for sampling
and kinds of products processed plastifume and gases Part 4: Fume data sheets
cally Part 3: chemical composition and
13. Tong H. Nakata K. Tonaka M. and Ushio
kinds of products
M. Mechanism of fume reduction in
10. PN-EN ISO 18273:2007P Welding conwelding Al-Mg alloys using alternating
sumables Wire electrodes, wires and
current pulsed metal inert gas method.
rods for welding of aluminium and aluIIW. Doc. XII-1842-05
minium alloys Classification
No. 4/2013
21