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Abstract
A pipe of Aluminium Alloy 5083 for Liquefied Natural Gas (LNG) transport has been welded by the Gas
Tungsten Arc Welding process (GTAW). The welding was conducted following the welding parameters in
four passes and using an ER 5356 filler metal according to standard American Welding Society (AWS) and
Argon as shield gas.
A Metallographic studies (Optical Microscopy and Scanning Electron Microscopy) and mechanical tests
(Micro Hardness Vickers test and Tensile Test) were made to determine microstructure evolution and
mechanical properties of weld joint.
Key words:
Aluminium alloys welding, HAZ, hardness, tensile strength & yield strength, microstructures.
1.
INTRODUCTION
The necessity to reduce weight and exhaust emissions, improve fuel economy has led to increased use of
lightweight materials such as Aluminium alloys. Among the alloys, AA 5083 is used in many fields of liquefied
natural gas (LNG) transport and storage tanks, ships, vehicles, and high pressure vessels for his good
strength and welding properties, etc.
Welding is an important manufacturing technology in Aluminium alloy application. The optimisation of the
welding process requires a good understanding of the microstructures generated by the rapid temperature
rise in the heat affected zone. Improvements to welding technique are desirable as it is one of the methods
showing greatest potential for application in industry.
2.
EXPERIMENTAL PROCEDURE
2.1
The studied material, 5083 Aluminium alloy pipe, 6 diameter and 8 mm thickness, used in LNG
transportation for low temperature. The chemical compositions of base and filler metal are given in "Table 1".
Table 1 Chemical composition of the Aluminium base material and filler metal, wt. %.
Materials
Al
Si
Mg
Ti
Cr
Mn
Fe
Ni
Cu
Zn
Sn
AA 5083
94,3
0,45
3,95
0,03
0,41
0,48
0,22
0,01
0,03
0,03
<10
ER 5356
94.58
0.25
4.5
0.06
0.05
0.05
0.40
0.10
-3
Pb
<10
/
-3
S
0,01
/
Weld was made by joining two pipe coupon tests by means of Gas Tungsten Arc Welding (GTAW). The
configuration of the joint groove was V-shaped and the weld was completed in four passes using ER 5356
filler metal in position 5G (pipe with its axis horizontal and with welding groove in vertical plane. Welding was
done without rotating the pipe) [2] "figure 1". Cracking and porosity are major concerns in welding Aluminium
alloys. To reduce the defects and to have good weldability, Argon as shield gas have used, which play an
important role in reduction of generation of defects and protection of weld pool from oxidation (Aluminium
being very reactive with oxygen contained in the atmosphere). Additional requirements of the shielding gas
are a stable arc root mechanism, efficient shielding of the weld pool and adjacent area, and good weld
penetration with a smooth weld bead profile. But they have very different characters [1].
4
3
2
1
Root
GTAW
5G
AC
ER 5356
2.4
1.6 2.0
60 90
11 18
Ar
10 - 20
Fill
GTAW
5G
AC
ER 5356
2.4
1.6 2.0
80 160
11 18
Ar
10 - 20
Cap
GTAW
5G
AC
ER 5356
2.4
1.6 2.0
80 160
11 18
Ar
10 20
HV3
HV2
HV1
The AA 5083 is an Aluminium alloy that relies solely upon cold work and solid solution strengthening for his
strength properties. It differs from heat treatable alloys in that it is incapable of forming second-phase
precipitates for improved strength.
Before examining the weld, a metallographic examination of the base metal presents a granular structure
slightly stretched out "figure 4". The size of the grains varies between 20 and 40 m. The second phase has
a same size that the matrix. Analyses performed with Energy Dispersed Spectrum (EDS) indicate that some
are rich in magnesium and others contain iron and manganese "figure 4". These second phases are the
Al3Mg2 and an intermetallics were either Al6(Fe, Mn) or Al6Mn and Al3Fe.[3]
HV 2
HAZ
WM
HAZ
MB
20
80
60
40
MB
HAZ
WM
HAZ
MB
10
15
20
Distance (mm)
25
30
60
40
MB
HAZ
WM
HAZ
10
15
20
MB
0
0
80
20
20
100
0,3
MB
Hardness HV 0,3
60
120
100
0,3
Hardness HV 0,3
80
40
HV 3
120
100
0,3
Hardness HV 0,3
120
10
15
20
25
30
Distance (mm)
25
30
Distance (mm)
reduction in the stress before the metal exhibits a plastic flow region with stress again increasing with strain
until the ultimate stress is reached and the stress reduces to the point of failure.
In most cases, the elastic limit or yield point is not clearly defined on the stress/strain curves for aluminium
alloys, this is apparent by looking at figure 8. For this reason the point of departure from the elastic range
has to be defined arbitrarily. Today, however, 0.2% is the international norm. The failure for the tensile test
occurred at the welded joint. The tensile strength value is 257,73 Mpa, a yield strength is 246,59 Mpa and a
deformation about 17,01 %. Furthermore, the tensile test can ensure that the minimum strength
requirements, as there are defined by the ASME Sec IX standards [2], are met after welding. For AA welds,
the minimum strength prerequisite is the same with that of the parent metal, set at 270 Mpa for the AA 5083.
The obtained value is less about 4.5 % of the limit value.
The weld metal of these aluminium alloys is typically the weakest part of the joint and is the location of failure
when the joint is loaded in tension. This is in contrast to most heat-treatable aluminium alloys, where the
heat affected zone often is the weakest link.
UTS (Mpa)
The absence of precipitate-forming elements in this alloy becomes a positive attribute when considering
weldability, because many of the alloy additions needed for precipitation hardening can lead to liquation or
hot cracking during welding. In addition, joint efficiencies are higher in this alloy because the heat-affected
zone (HAZ) is not compromised by the coarsening or dissolution of precipitates. When these alloys are
welded, microstructural damage is incurred in the HAZ. Unlike the case of heat treatable alloys, whose
strengthening precipitates may dissolve or coarsen, the HAZ damage in non-heat-treatable alloys is limited
to recovery, recrystallisation, and grain growth. Thus, loss in strength in the HAZ is not nearly as severe as
that experienced in heat-treatable alloys.
Deformation %
CONCLUSION
In this paper, the effect of the microstructural changes that accompany a common welding
technique, on the mechanical properties is investigated. Based on the analysis described above, the
following conclusions are drawn:
Metallographic examination of the base metal presents a granular structure a slightly stretched out
with a grains size varies between 20 and 40 m.
Applying the welding parameters, weld was performed by GTAW process, shielded argon gas.
Argon as shielding and purging is the most common gas, which play an important role in reduction of
generation of defects and protection of weld pool.
The HAZ has a coarse grain structure than the base metal.
The microstructure observed in the HAZ was the successive thermal cycle of multi-pass.
Cumulative effect of thermal cycles after each passes resulted in softening of the lower pass and of
the adjacent parent metal.
Hardness tests values vary between 80 and 100 HV, and a softening is apparent for the HAZ area.
The weld metal is the weakest part of the joint and is the location of failure when the joint is loaded in
tension.
The as-welded specimens were subjected to uniaxial tensile tests. The UTS value is 257.73 MPa.
REFERENCES
[1]
J.H. Kim, D.H. Park, J. Korean Weld. Soc. 12 (1) (1994) 715.
[2]
ASME Boiler & Pressure Vessel Code, Section IX. Welding and Brazing Qualifications.
[3]
Calcraft RC, Wahab MA, Viano DM, Schumann GO, Phillips RH, Ahmed NU. The development of the welding
procedures and fatigue of butt-welded structures of aluminium-AA5383. J Mater Process Technol 1999; 92
93:605.
[4]
R.P Martukanitz and P.R. Michnuk, Sources of Porosity in Gas Metal Arc Welding of Aluminium, Trends in
Welding Research, ASM INTERNATIONAL, 1982, P 315-330.