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Tony Paterson
Specific applications
Welding problems
What is a casting?
three dimensional shape formed from the melt (highly
complex shapes possible)
cf wrought flats - one dimensional (thickness)
wrought extrusions two dimensional
wrought forgings simpler three dimensional
(hot or cold formed from solid or semi solid cast)
Generally non homogenous structure due to directional
solidification
Produced using various processes (sand, permanent mould
(gravity and low pressure laminar
flow), high
pressure die casting
Specific applications
Welding problems
Aluminium Casting
Designations
Cast Alloy Designation (US)
US 3 digit number, plus 1 decimal
Al+
Cu Si/Cu/Mg Si Mg
Zn
Sn Other
1xx.x 2xx.x 3xx.x 4xx.x 5xx.x 7xx.x 8xx.x 9xx.x
Non-heat-treatable
Heat-treatable
AXXX.X
Aluminium Casting
Designations Cast Alloy Designation
(EN)
EN 5 digit number
Al+
Cu Si/Mg Si/Cu/Mg Si.12% Mg Zn/Mg Master
21xxx 41xxx 45xxx
44xxx 51xxx 71xxx 9xxxx
42xxx 46xxx
43xxx 47xxx
Non-heat-treatable
Heat-treatable
ACXXXXX
Principle Alloying Element
Alloy Groups (with principal element)
Arbitrary
Generally 0
0 except for aerospace
Examples:
AC 42100 is an Al/Si/Mg alloy .
AC 45100 is an Al/Si/Cu/Mg
alloy
Second symbol: Al
Third and following: Alpha numeric
Si/Cu Si/Mg
LM2
LM4
LM20
LM21
LM22
LM6
LM9
LM25
Mg
LM5
Other (piston)
LM28
LM13
LM24
Non-heat-treatable
Heat-treatable
Specific applications
Welding problems
Processes
Heat treatable
EN 42000 (LM25, AlSi7Mg)
EN 42100 (AlSi7Mg0,3)
weldability, castability
hardeners
Aluminium 660oC
650oC Mg
630oC Sb
420oC Zn
231oC- 327oC
Se, Sn, Bi, Cd, Pb,
97,7oC Na
44.2oC P-
Free machining
Grain modifiers
(casting) affects
micro porosity
(early freeze c.f. Si)
Composition cf wrought
alloys
20
2xxx
5xxx
Dilution by 4043 thus choose 5356
6xxx
Dilution by 4043 avoid 5356
Excellent
******
A **
*******
*
Very good
****
B ****
*
***
Good
***
*
(1xxx)
* ** * (3xxx, 5xxx, 51000 (LM0,LM5))
**
**
***
**
**
** (LM20)
C
*
Poor
********
********
(2xxx, LM4, 21,22,24,26)
D
0.1
0.2
0.3
0.5
3 3+
22
Silicon
Si improves fluidity, feeding and hot tear resistance.
Si increases hardness, reduces ductility &
machinability.
Si content is related to casting process
Sand casting 5 - 7% Si
Permanent mould 7 - 9% Si
Die casting 8 - 12% Si
Copper
Basis of heat treatable alloys
Improves strength, hardness, thermal conductivity
Decreases castability and hot tear resistance
Allows most hardening in 4 - 6% range
Copper base alloys above about a 0,4% limit
Iron
Normally not added but picked up from furnace
Forms many intermetallic phases
Increases elevated temperature strength
Improves hot tear resistance
Reduces ductility
Too high reduces castability
Flowability and feeding characteristics
Magnesium
Strengthening in AlSi alloys
Premium grade alloys have 0,4 - 0,7%Mg
No benefit above 0,7%
High corrosion resistance
Lead
Added up to 0,35%Pb to improves machinability by
to 0,05%
Specific applications
Welding problems
Chemical
designation
UK
BS1450/
AEA
France
NF A50
Germany
DIN 1725
Italy
UNI
USA
AA / ASTM
A5
Al99,5H
3950
150.1
A7
Al99,7H
3950
Japan
JIS H5202
H5302
LM0
Al 99,7
AlSi7Mg0,3
AEA 44525
(A S7G03)
(G AlSi7Mg)
42100
AlSi7Mg (Fe)
LM25
A-S7G03
G- AlSi5Mg
42200
AlSi7Mg(0,6)
AEA 44530
(A-S7G06)
(G -AlSi7Mg)
43100
AlSi10Mg
LM9
A-S10G
(G
AlSi10Mg)
43200
AlSi10Mg(Cu)
(LM9)
(A-S9G)
44000
AlSi11
(LM9)
A-S13
(G AlSi12)
44100
AlSi12(Fe)
LM6
A-S12U
G AlSi12
44200
AlSi12
AEA46330
/LM6
A-S13
44300
AlSi12(Fe)
(LM20)
A-S12
3599
A356,1
AC4C
A357
3049
A360
AC4A
A360
4514
A413
AC3A
AC3A
(G AlSi12)
Chemical
designation
UK
BS1450/
AEA
France
NF A50
Germany
DIN 1725
Italy
UNI
USA
AA /
ASTM
Japan
JIS H5202
H5302
7369/4
A308
AC2A
AlSi6Cu4Mn
LM21
A-S5UZ
G-AlSi6Cu4
45100
AlSi5Cu3Mg
(LM4)
(LM22)
A-S5U3G
(G-AlSi6Cu4)
45200
AlSi5Cu3Mn
LM4
A-S5U3
(G-AlSi7Mg)
3052
A319.2
AC2A
45400
AlSi5Cu4Mn
LM22
A-S5U
G-AlSi6Cu4
3052
A319.2
AC2A
46000
AlSi9Cu3
(LM26)
A-S10G
A335
AC4B
46100
AlSi9Cu3
LM2
A-S10UG
5067
A384.1
ADC12
46200
AlSi9Cu3(Fe)
(LM24)
A-SGU3
46500
AlSi9Cu3(Fe)
(Zn)
LM24
A-S9U3
G-AlSi8Cu3
5075/3601
A380.1
AC4B/
ADC10
47000
AlSi12(Cu)
LM20
A-S12
G-AlSi12(Cu)
5079
A313.1
47100
AlSi12Cu1
(Fe)
(LM6)(LM20)
A-S12
G-AlSi12(Cu)
Chemical
designation
UK
BS1450/
AEA
France
NF A50
Germany
DIN 1725
Italy
UNI
USA
AA /
ASTM
Japan
JIS H5202
H5302
A204.2
AC1B
(KS 2811)
A392.1
(AC9B)
(KS 1275)
A336.0
AC8A
Al Cu4MgTi
AEA 24850
A-U5GT
AlMg3
LM5
A-G3T
G-AlSiMg5
3059
Piston Alloys
48100
AlSi18Cu1
Mg1Ni1
LM28
48000
AlSi12Cu1
Mg1Ni1
LM13
A-S12UN
applications
LM5 best if bright finish to be maintained
Specific applications
Welding problems
0,35%Pb
High strength because of Cu and Fe
Good castability because of high Si
Not weldable because of Cu
Non heat treatable
LM25
LM20
LM9
LM6
LM5
LM4
4043
4043
4043
4043
Selection of4043
filler rods
and wires
for MIG
and 5356
TIG welding
4043
NR
4043
NR
5356
4043
7020
NR
NR
NR
NR
5356/5556
NR
LM4
4043
4043
4043
4043
NR
4043
LM5
NR
NR
NR
NR
5356/5056
NR
LM6
4043/4047
4043/4047
4043/4047
4043/4047
LM9
4043/4047
4043/4047
4043/4047
LM20
4043/4047
4043/4047
LM25
4043/4047
Specific applications
Welding problems
Repair Welding
Casting is heat treatable and has been hardened
Welding will over age HAZ
Can do simple repairs in T6 or T7 temper
Better to weld in F or T2 condition
Large extensive repairs only in F or T2
Anneal before welding
castings
Use 4043 (6%Si) or 4047 (12% Si) filler
Heat input 0,8 - 1,6 kJ/mm
Slow cool
Weld strength very close to base metal
Cosmetic Repair
Non heat treatable
Preheat as appropriate
Clean thoroughly
Weld with 4043 or 4047 filler
Slow cool <15C per minute
Cosmetic Repair
Heat treatable alloy
Casting is in as cast F temper
Preheat and clean thoroughly
Use 4043 filler
Low heat input minimises precipitation aging
Post weld aging enhances weld strength but 4043 not
heat treatable
Build-up of Castings
Very similar to cosmetic repair procedure
Depends on alloy and temper
Preheat depends on casting size and complexity
Aluminium to Steel
Very difficult ~ intermetallic compounds, melting
temperatures, expansion
Can tin steel, then with tin/aluminium then use
aluminium with TIG welding (used for welding
anode stems to steel anode inserts)
Usually use friction welding (not friction stir)
Aluminium to Copper
Used for electrical terminations
Can coat copper with silver or silver alloy
Then join with Al or Al/Si filler without penetrating
Specific applications
Welding problems
General Considerations
Avoid unnecessary stresses
No sudden thickness changes ~ use tapers
Ensure good fit up ~ 1 - 1,5 mm
Good alignment is essential
Use correct weld preparation ~ check drawing
General Considerations
Clean the joint properly
Aluminium very susceptible to contamination
General Considerations
Create the right conditions for welding - physical
Dry (RH<65%), warm, draught free conditions are best
(Be careful at coast or early on winter mornings on highveld)
leads to porosity
Draughts can disrupt inert gas flow and cause oxide
inclusions
(Note - too high an inert gas flow disrupts
the molten pool and causes porosity)
General Considerations
Ensure consumables are suitable
Gas must be 99,995% pure minimum - normally Argon
Keep wire and filler rods clean and dry (remove or
cover at night)
Clean using stainless steel wire wool never use
Scotchbrite as it leads to porosity.
No greasy gloves
Old MIG wire will become contaminated and cause
oxide contamination
preparation
Tungsten carbide burrs are suitable for final
cleaning
Do not use (corundum) grinding disks for final
cleaning
Welding problems
Gas porosity in aluminium welds always caused by hydrogen
Low solubility in solid and high solubility in liquid aluminium
Alloying elements Si, Cu, Mn and Zn lower hydrogen solubility
Alloying elements Mg, Ni and Ti increase hydrogen solubility
Some hydrogen in molten metal comes from disassociation of
water vapour in the air, burner fuels or damp fluxes.
To avoid hydrogen pick-up the oxide layer on the liquid
aluminium should not be disturbed as if protects the metal.
Welding problems
Gas porosity in aluminium welds always caused by hydrogen
(Low solubility in solid and high solubility in liquid aluminium)
Welding problems
- Gas Porosity in welds
Welding problems
Cracking in aluminium is always hot cracking
Strength of solidifying metal is too low to resist
Welding problems
Hot Cracking cont..
Weld bead chemistry - Select suitable filler metal
Higher alloy content allows for dilution
Hot crack sensitivity depends on alloy content.
Welding problems
Composition relationship between filler/parent metal and weld cracking
(Note: long copper sensitivity above 0,25%)
2xxx
5xxx
Dilution by 4043 thus choose 5356
6xxx
Dilution by 4043 avoid 5356
Good
Fair
Poor
5
4
a
3
2
b
1
d
c
4
3
2
Silicon in the Weld Bead (%)
Specific applications
Welding problems