The welding of aluminium castings

Tony Paterson
Welding of aluminium castings
Objectives:
• What is a casting
• Why weld a casting
• Casting designations
• Which castings are weldable
Effect of casting processes
Effect of welding composition
• Alloys used in RSA

• Welding of selected casting alloys

• 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
 Why weld a Casting?
 Join a casting to wrought material
 Joining several castings together
 Build up a casting
 Worn area or manufacturing
 Join casting to other metal
 Physical damage to old casting
 Repair of superficial defect in a new casting
 Repair of unavoidable shrinkage porosity in new
casting
 Note that not all castings are weldable
 Why weld a Casting?
 Join a casting to wrought material

Welding compromises the strength of tempered aluminium because it

reverses the temper effect

It is desirable to choose the position and nature of welds to limit the

impact of this loss of strength.

From a structural point of view a casting forms a good corner stress

transfer unit in three dimensional structural applications as it
potentially displaces welds to low stress areas.

Whilst adhesive bonding is sometimes called for, some

casting alloys are weldable.
Welding of aluminium castings
Objectives:
• What is a casting
• Why weld a casting
• Casting designations
• Which castings are weldable
Effect of casting processes
Effect of welding composition
• Alloys used in RSA
• Welding of selected casting alloys

• Specific applications
• Welding problems
 Aluminium Casting Designations
Which alloy is which - Cast Alloy Designations
There is no single universally accepted designation system

Designations systems include:

 US 3 digit number, plus 1 decimal
 EN 5 digit number (RSA standard since 1990’s)
 Chemical designations (eg old DIN)
 UK discontinued LM series still commonly cited in RSA
 Others – eg old eastern Europe
 Others Far East – including Japan

Note: From a welding point of view we need to understand which alloy

we are dealing with as not all are weldable – in particular most Cu
(2xx.x)and ZnCu (7xx.x) alloys are practically unweldable.
There are exceptions.
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
Aluminium Casting Designations
Cast Alloy Designation (US)

(Modifications (sometimes have a prefix

[A,B,C]) depending on the element
AXXX.X
Principle Alloying Element
Alloy Number
Form - Final Casting (.0) or Ingot (.1 or .2)*
*Depending on Purity Limits
• Example 535.0 is an Al/Mg alloy, with no
modification, assigned alloy number 35, for
final casting
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
Aluminium Casting Designations
Cast Alloy Designation (EN)

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
 Aluminium Casting Designations
Cast Alloy Designation (Chemical) – similar to wrought
 Chemical designation (older German specifications)

 First symbol: AB (billet) or AC (casting) or (A) or G (DIN)

 Second symbol: Al
 Third and following: Alpha numeric
– Alpha - Main element or elements in order of decreasing
nominal content (or, if equal, in alphabetical order – up to a
maximum of four elements) followed by numbers.
- Numeric - represent the mass percentage contents to the
nearest 0,5%, or, if less than 1%, the nearest 0,1%)
Weldability: take care with alloys where Cu>0,25 -0,4%
Aluminium Casting Designations
Cast Alloy Designation (BS now superceded)

UK discontinued LM series (unsystematic – WW2 base)

Still used in RSA and cited in reference literature
Al

Cu Si/Cu Si/Mg Mg Other (piston)

LM0 LM2 LM6 LM5 LM28
LM4 LM9 LM13
LM20 LM25
LM21
LM22
LM24
Non-heat-treatable
Heat-treatable
Welding of aluminium castings
Objectives:
• What is a casting
• Why weld a casting
• Casting designations
• Which castings are weldable
Effect of casting processes
Effect of welding composition
• Alloys used in RSA

• Welding of selected casting alloys

• Specific applications
• Welding problems
Which castings are weldable?
 Process
 Composition
 Which castings are weldable?
Process
Alloys
Wrought alloys All except > 0,25% copper
addition - (some exceptions
<0,4%) and free machining alloys
Cast alloys All except > 0,25% copper
additions, and free machining
alloys
Processes
All - Rolling, extrusion,
forging, etc
Sand, gravity, permanent
mould, low pressure.
Not standard high pressure
die casting (i.e. unless
vacuum cast.)
Weldable Cast Alloys
 Non heat treatable
 EN 44100 (LM6, AlSi12)
 EN 44000 (AlSi11)
 EN 43100 (LM9, AlSi10Mg)
 EN 5100 (LM5)
 Heat treatable
 EN 42000 (LM25, AlSi7Mg)
 EN 42100 (AlSi7Mg0,3)
Which castings are weldable?
Composition
 Based on aluminium silicon
 Main elemental additions of Cu, Mg, Fe, Mn, Ni, Zn, Pb
Other elemental additions include a wide additional range.
 Alloy elements modify casting characteristics
 Also influence hardness, fluidity, machinability,
weldability, castability
Which castings are weldable?
Composition - What do we add - Summary

1852oC – 2625oC Zr, Ti, Cr, B, V, Mo Grain refiners

(never melts)
1410oC Si
MgSi composition 6xxx
1245oC Mn
1150oC Fe
1083oC Cu
768oC Sr
hardeners
Aluminium 660oC
650oC Mg
630oC Sb Grain modifiers
420oC Zn (casting) affects
231oC- 327oC micro porosity
Free machining (early freeze c.f. Si)
Se, Sn, Bi, Cd, Pb,
97,7oC Na
44.2oC P-
Which castings are weldable?
Composition – cf wrought alloys

20
 Which castings are weldable?
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
Which castings are weldable?
Compostion
Welding
Rating
****** (1xxx)
Excellent A ** ******* *** * ** * (3xxx, 5xxx, 51000 (LM0,LM5))

**** * * ** * (6xxx, LM25, LM6)

Very good B ****
* *** ** *** ** ** ** (LM20)
Good C
* ********
********
Poor D (2xxx, LM4, 21,22,24,26)

0.1 0.2 0.3 0.5 1 2 3 3+

NOTE Log scale! ln Cuupper limit% (wrought and cast alloys)

(Other alloy elements, eg silicon, also have a role)

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

weldability, corrosion resistance and suitability for
decoration
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
enhancing intergranular chip breaking

 Not suited to food grade products as these limit lead

to 0,05%
Welding of aluminium castings
Objectives:
• What is a casting
• Why weld a casting
• Casting designations
• Which castings are weldable
Effect of casting processes
Effect of welding composition
• Alloys used in RSA

• Welding of selected casting alloys

• Specific applications
• Welding problems
Designations of comparable casting alloys
(unalloyed and aluminium silicon)
CEN Chemical UK France Germany Italy USA Japan
designat- BS1450/ NF A50 DIN 1725 UNI AA / ASTM JIS H5202
ion AEA H5302
Unalloyed aluminium – generally weldable

Al 99,5 LM0 A5 Al99,5H 3950 150.1

Al 99,7 A7 Al99,7H 3950
Aluminium Silicon – generally weldable
42000 AlSi7Mg0,3 AEA 44525 (A –S7G03) (G AlSi7Mg)

42100 AlSi7Mg (Fe) LM25 A-S7G03 G- AlSi5Mg 3599 A356,1 AC4C

42200 AlSi7Mg(0,6) AEA 44530 (A-S7G06) (G -AlSi7Mg) A357

43100 AlSi10Mg LM9 A-S10G (G – 3049 A360 AC4A
AlSi10Mg)

43200 AlSi10Mg(Cu) (LM9) (A-S9G) A360

44000 AlSi11 (LM9) A-S13 (G –AlSi12)

44100 AlSi12(Fe) LM6 A-S12U G –AlSi12 4514 A413 AC3A

44200 AlSi12 AEA46330 A-S13 AC3A

/LM6
44300 AlSi12(Fe) (LM20) A-S12 (G –AlSi12)
Designations of comparable casting alloys
(aluminium silicon copper)
CEN Chemical UK France Germany Italy USA Japan
designat- BS1450/ NF A50 DIN 1725 UNI AA / JIS H5202
ion AEA ASTM H5302

Aluminium Silicon Copper – generally not weldable

45000 AlSi6Cu4Mn LM21 A-S5UZ G-AlSi6Cu4 7369/4 A308 AC2A

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) LM24 A-S9U3 G-AlSi8Cu3 5075/3601 A380.1 AC4B/

(Zn) ADC10

47000 AlSi12(Cu) LM20 A-S12 G-AlSi12(Cu) 5079 A313.1

47100 AlSi12Cu1 (LM6)(LM20) A-S12 G-AlSi12(Cu)

(Fe)
Designations of comparable casting alloys
(Aluminium copper/aluminium magnesium and piston alloys)
CEN Chemical UK France Germany Italy USA Japan
designat- BS1450/ NF A50 DIN 1725 UNI AA / JIS H5202
ion AEA ASTM H5302
Aluminium Copper – not weldable
21000 Al Cu4MgTi AEA 24850 A-U5GT A204.2 AC1B

Aluminium Magnesium – weldable

51000 AlMg3 LM5 A-G3T G-AlSiMg5 3059

Piston Alloys
48100 AlSi18Cu1 LM28 (KS 2811) A392.1 (AC9B)
Mg1Ni1
48000 AlSi12Cu1 LM13 A-S12UN (KS 1275) A336.0 AC8A
Mg1Ni1

Note: Designations in brackets are considered fairly comparable

For export purposes the LM series is not recognised
Alloys selection for weldability/
corrosion resistance
 Generally corrosion resistance and weldability run in parallel

 LM0, LM2, LM4, LM5, LM6, LM9, LM21, LM24, LM 25,LM31

(low Cu alloys) resistant to weathering attack .
Other alloys require protection by anodising or organic finishes

 LM0, LM5, LM6, LM9, LM20, LM25, LM31 suited to marine

applications
LM5 best if bright finish to be maintained
Welding of aluminium castings
Objectives:
• What is a casting
• Why weld a casting
• Casting designations
• Which castings are weldable
Effect of casting processes
Effect of welding composition
• Alloys used in RSA

• Welding of selected casting alloys

• Specific applications
• Welding problems
Alloys used in RSA
 EN 44100 (LM6, AlSi12)
 10,5 – 13,5%Si; 0,15%Cu
 Widely used for sand and chill castings
.
 Poor machinability
 Good weldability
 Not heat treatable
Cast Alloys cont..
 EN 46500 (LM24, AlSi9Cu3(Fe)(Zn))
 8,0 – 11,0%Si; 2,0 – 4,0%Cu; 1,3%Fe;
0,35%Pb
 High strength because of Cu and Fe .
 Good castability because of high Si
 Not weldable because of Cu
 Non heat treatable
Cast Alloys cont..
 EN 42000 (LM25, AlSi7Mg)
 6,5 – 7,5%Si; 0,2%Cu
 Larger castings ~ cylinder blocks etc.
 High strength
 Good castability
 Heat treatable
 Weldable
Cast Alloys cont..
 EN 46100 (LM2, ADC12, AlSi11Cu2(Fe))
 10,0 – 12,0%Si; 1,5 – 2,5%Cu
 Pressure die casting alloy specifically
 Good castability
 Not weldable
 Non heat treatable
Cast Alloys cont..
 EN 44000 (ALSi11)
 Very fluid permanent mould alloy
 Traditionally used for alloy wheels
 Good ductility, moderate strength
 High impact strength
 Non heat treatable
 Weldable
Cast Alloys cont..
 EN 42100 (AlSi7Mg0.3)
 Used for alloy rims, premium aerospace castings,
nuclear plant, marine parts
 High strength, good ductility
 Good corrosion resistance
 Heat treatable
 Weldable
Cast Alloys cont..
 EN 43100 (LM9, AlSi10Mg)
 10,0 – 11,8%Si; 0,25 – 0,45%Mg
 Most fluid permanent mould alloy available
 Used for intricate castings ~ feedability
 Non heat treatable
 Good weldability ~ high ductility
 Cast Alloys – filler alloy choice
Selection of filler rods and wires for MIG and TIG welding
Parent metal LM25 LM20 LM9 LM6 LM5 LM4
combination
1070, 1200, 1350, 4043 4043 4043 4043 5356 4043
5251, 5454,
6082, 6061, 6063,
5083 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
Welding of aluminium castings
Objectives:
• What is a casting
• Why weld a casting
• Casting designations
• Which castings are weldable
Effect of casting processes
Effect of welding composition
• Alloys used in RSA

• Welding of selected casting alloys

• 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
Non Heat Treatable Casting
 Preheat 100C up to 8 mm thick
 340 - 400C for heavy or intricate
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
Heat Treatable Alloy cont..
 Preheat 100 - 400°C (short period to avoid anneal)
 Use 4043 filler metal
 Solution anneal ~ also stress relieves weld
 Heat treat as required – but 4043 NHT
Cosmetic Repair
 Non heat treatable
 Preheat as appropriate
 Clean thoroughly
 Weld with 4043 or 4047 filler
 Slow cool <15°C 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
Welding Multiple Castings
 Preferably F or T2 condition
 Lowest strength in base metal
 Preheat and clean
 Weld with 4043 or 4047 filler
 Non heat treatable ~ slow cool
 Heat treatable ~ Solution anneal and harden
Welding Cast to Wrought
 Same principles as casting to casting
 Wrought material will lose strength
 Hot weld cracking is main problem
 Caused by shrinkage & other stresses
 Several techniques can be used
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
the silver layer
 Can use MIG spot welding
 Usually use friction welding
Welding of aluminium castings
Objectives:
• What is a casting
• Why weld a casting
• Casting designations
• Which castings are weldable
Effect of casting processes
Effect of welding composition
• Alloys used in RSA

• Welding of selected casting alloys

• 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
(hydro carbons or oxides)
 Solvent wipe to degrease 50 mm either side
 Clean stainless steel wire brush
 Do not use grinding disks
 Tungsten carbide burrs are suitable
 Weld within three hours of cleaning
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)
 Al very susceptible to hydrogen from moisture or oils
– 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
Cutting and Preparing Al
 Cannot use oxy fuel
 Aluminium is not fit up tolerant – cannot fill significant
gaps
 Plasma cutting widely used
 Cut surface is rough, oxidised, must be dressed
 HT alloys crack 2 - 3 mm into plate ~ finish cut
 Non HT alloys just need mechanical dressing
 Woodworking band saw works well
 Circular saws and portable jig saws are useful
 Mineral oil lubrication is needed
Cutting and Preparing Al cont..
 Planers, routers and edge mills for edge
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

stresses during cooling
 Reduce heat input
 High travel speed, lowest weld parameters
 Preheat base metal ~ reduce cooling rate
 Change joint design to minimize dilution
 Change restraining jigs or fixtures
 Use correct depth to width ratio
 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
 Figure 1. Resistance to hot cracking

8 Good

7 Fair

Poor
6
Filler Alloy 5356

4
a

2
Parent Alloy 6061
b

1 d Filler Alloy 4043

c

0 1 2 3 4 5 6
Silicon in the Weld Bead (%)
Welding of aluminium castings
Topics covered:
• What is a casting
• Why weld a casting
• Casting designations
• Which castings are weldable
Effect of casting processes
Effect of welding composition
• Alloys used in RSA

• Welding of selected casting alloys

• Specific applications
• Welding problems
The welding of aluminium castings

Tony Paterson (082 602 4517)

Questions??