Aluminium GMAW Welding.docx

8/13/2019 Aluminium GMAW Welding.docx

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Written by Ed Craig www.weldreality.com

Aluminum Section 2. Data and Weld Tips.

ED'S MIG EQUIPMENT RECOMMENDATIONS FOR COSTEFFECTIVE PULSED ALUMINUM WELDS.

OTC Daihen and Fronius make the best pulsed MIG power sources available for bothstainless and aluminum welds on "thin gage" or "high volume" applications. The OTCequipment is the most cost effective pulsed MIG equipment and provides superiorpulsed MIG output characteristics than comparative North American pulsed MIGequipment.

Note: For more weld equipment data see weld equipment section.Click here.
http://www.weldreality.com/equipment_evaluation.htmhttp://www.weldreality.com/equipment_evaluation.htmhttp://www.weldreality.com/equipment_evaluation.htmhttp://www.weldreality.com/equipment_evaluation.htm


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ALUMINUM WELD TIPS AND DATA:

Warning: To avoid cracks. Mixing alloys as typically occurs in welding dissimilar aluminum

alloys can increase the crack sensitivity. When selecting the aluminum filler metal, examinethe base alloy and filler alloy combination and avoid a final mix of alloys high in both Mg andCu content.

Poor wire feed is the prime cause of wire burn back to the contact tip.

In contrast to the 5xxx series, the 4xxx filler metals typically have lower ductility and lessshear strength in fillet welds, these wires will also have more wire feed issues than the samesize 5xxx wires.

The 5xxx filler metals provide the highest weld strength for none heat treatable alloys.Magnesium 0.5 to 3% provides a weld which is crack sensitive. The Al - Mg alloys with lessthan 3% Mg can be welded with the Al - Si 4xxx alloys as the magnesium silicides increase

ductility and increase the crack sensitivity.

For optimum wire feed, use minimum amount of brake on wire spool.

To feed the soft alum wire, use rigid, hard plastic instead of softer nylon.

For inlet - outlet guides ensure nylon or teflon is used.

To minimize the wire tension effects on the soft alum wire, use U groove drive rolls, withchamfered edges. Use minimum wire feed tension.

Manual welding aluminum with a traditional MIG torch and an 0.046 wire, use a conventional

10 foot torch with a plastic liner.

If a robot is used and the wire feed control is mounted on the robot, a push pull system isnot necessary if an Alcotech or similar MIG wire controlled tension, dee-reeler is utilized.


Use higher flow rates forMIG welding Aluminum 40 - 60 cfhr for argon. Forhelium argon mixes, 50 - 100 cuft/hr. If you use anargon flowmeter and a helium mix and set at 40cuft an hr you may get 50% more gas than youneed. For helium argon mixes use a flow meterdesigned for helium.

Avoid rigid clamps onfixtures, use minimum restraint to avoid cracking.

With aluminum weld heat buildup in the part is rapid consider yourweld sequence carefully, do the thin parts or gaps first. Consider the


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use of heat quench components on your fixtures in close proximity tothe welds.

Excess restraint on aluminum fixtured parts can result in longitudinalcracking.

Increasing the weld size will decrease the opportunity for longitudinalcracks.

To reduce alum transverse cracks reduce weld heat input. Lower parameters and increaseweld travel rates.

To reduce crater cracks use a back step technique, and with a robot use lower weld data forthe crater fill data.

To minimize center line cracking ensure sufficient convex fillet throat and use low voltage.

To increase weld penetration, increase wire feed rate, use the lowest possible voltage, lowerweld speed.

Weld Technique and craters: With aluminum welding, crater cracking is the cause of manycrack influenced weld / part failures. Crater cracks results from the concave thin weld endsand the high thermal expansion and contraction of the aluminum as the weld end cools and

tears apart.

Welders should buildup craters to form a convex or mound shape. As the weld cools, theincreased weld mass from the convex shape of the crater weld will compensate forcontraction forces. Use the crater fill data equipment options, a back step technique or startand stop the weld at the weld completion.


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Pulsed MIG is especially suited to aluminum weld applications 0.040 to 0.100. For alum partsOver >4 mm, traditional MIG spray transfer should provide superior fusion and less porosity.

In contrast to MIG welding steels, the pulsed MIG process provides real welding benefits.The lower, attainable pulsed spray current reduces weld burn-through and the lower pulsedcurrent with high conductivity - lower melting temperatures means you can use larger wires.Also with pulse less weld smoke and less ozone is generated

Pulsed MIG ideal for vert up welds, however with aluminum spray transfer can also be useddor all position welds.

With aluminum avoid weld weaves use stringer beads for multi-pass welds.

With aluminum use the largest wire sizes to avoid feed problems. Consider 0.046 thesmallest practical alum weld wire.

Wire sizes smaller than 0.046, < 1.2 mm can cause wire feed problems.

Use an helium argon mix for alum applications thicker than 6 mm and for applications whichrequire more weld penetration. Best helium mix, 60 helium 40 argon, Note it's important tokeep sufficient argon for it's cleaning action on the surface alum oxides.

Use the largest size nozzle to ensure complete gas coverage of the weld.

If wire burn back - contact tip issues occur, consider using the next size contact tip or drillyour tips 0.01 larger than the origional tip bore.

To avoid robot start issues, run the wire in at a faster wire feed rate than the weld wire feedrate.

As aluminum weld starts and weld ends can have lack of weld fusion, its beneficial to add tothe length of the welds and with a robot. At the weld starts, use seperate wire feed - voltagedata and techniques to deal with these concerns.

When the aluminum is anodized, silicon in the 4xxx alum wires can make the weld appeardarker. A change to a 5xxx wire will improve the appearance.


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MORE ALUMINUM WELD TIPS AND DATA:

Use Austenitic (300 series) stainless for back up bars or clamp materials close to thealuminum welds.

2XXX - 7XXX aluminum, watch out for start / stop weld cracks, consider run on run off tabs.

For base alloys with sensitivity to hot cracking such as 2xxx, consider 4xxx filler such as4145 or 4047. These alloys have a very low weld solidification temperature. A filler with avery low weld solidification temperature ensures the weld solidifies last after the base metal

has solidified and reached its max strength.

5XXX aluminum, max preheat / interpass temp 150F 65C to avoid cracks.

With aluminum alloys with 3.5 - 5.5 Mg to avoid cracking don't preheat over 250F (120C).

With aluminum alloys with 3.5 - 5.5 Mg to avoid cracking ensure max interpass temp is 300F

150C.

The common 6xxx heat treatable alloys lose approx. half their strength after welding. Postweld heat treat can improve the strength, if post heat considered ensure the filler isdesigned for the heat treatment.

Filler 4643 is for welding 6xxx alloys that require post heat treatment to attain improvedstrength.

Filler 5180 is used for the 7xxx series. It responds to heat treatment.

To lower HAZ cracks, use filler with the same or lower melt temp as base metal.

To prevent weld cracks, filler should have higher alloy content than the base metal.

4XXX - 5XXX is more crack sensitive when weld contains 0.5 to 2 % Si - Mg.

On thin alum sheet ER4047 is an alternative to ER4043.

5XXX or 6XXX pipe may also use ER5656

5183 or 5556 may be used instead of ER5356.

Don't use 5356 - 5183 5556 5654 for high temperature applications >150 F as stresscorrosion cracking can occur. Consider alloy 5554 asit contains less than 3% Mg.


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Be aware of trying to repair the none weldable alum grades. Those high cost alumcomponents found on aircraft, hang gliders, boats or sports equipment etc may containexotic alloys that can lead intergranular micro cracks and failure if heat is applied.

MORE ALUMINUM WELD TIPS AND DATA:

As thermal conductivity is very high for alum, the first 6 mmof the weld should provide a lack of weld fusion concern.That concern is increased when the aluminum componentsare >3 mm. The thicker the part, the greater the heat sink.The lack of weld fusion is typical in the first 6 mm of theweld. If your aluminum welds are >3mm and subject to

stress or fatigue, the following points will help in improvingweld start fusion and weld crater issues.

Some alum weld equipment provides a hot start featurewhich will enable you to set more weld current for the start.

With robots you can increase your arc start times and set aseparate, higher weld parameter weld schedule for the first 6mm of the weld.

If you need a weld three inches long on a part subject to stress, the designer would be wiseto make the weld three and a half to four inches long to compensate for weld start / stopissues.

To minimize the effects in the aluminum weld crater from the high thermal expansion andweld shrinkage (5 - 7%), try the following.

If purchasing new MIG weld equipment ensure it has a a good crater fill feature which lowersthe current in a controlled manner over a minuscule time period at the end of the weld.Those TIG welders who have used the weld current foot controls to ramp down the weldcurrent at the crater will be aware of the crater benefits when applied to a MIG weld.

If your robot weld equipment does not provide the current ramp down feature, then set aseparate weld schedule to commence for the last 6 mm of the weld. This weld schedule

would either provide a lower wire feed and voltage than the weld , or the schedule wouldhave the same wire feed setting as the weld with 2 to 6 lower volts than the weld voltage.

If your parameter control at the crater does not leave a convex weld, use the back steptechnique in which you get to the end of the weld and then come back 6mm with a lowerparameter setting.

Due aluminum's higher thermal conductivity, lower melting temperature and lower electricalresistivity than a steel, the alum MIG wire wire stick out is is extremely sensitive to current


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and voltage changes. This is one reason instability issues are a concern with the pulsed MIGprocess.

Warning: To avoid cracks. Mixing alloys as typically occurs in welding dissimilar aluminumalloys can increase the crack sensitivity. When selecting the aluminum filler metal, examinethe base alloy and filler alloy combination and avoid a final mix of alloys high in both Mg and

Cu content.

IF YOU USE ROBOTS FOR ALUM WELDS, ARE YOU AWARE OF THEFOLLOWING?

IF YOU HAVE A FULL UNDERSTANDING OF ALUMINUM AND ROBOTWELD PROCESS CONTROLS, YOU COULD USE SEPARATE WELDPARAMETER SCHEDULES IN A SINGLE WELD TO OVERCOME MANYOF THE UNIQUE ALUMINUM HEAT RELATED WELD AND WELDSTART ISSUES?IF THE WELD HEAT IS BUILDING UP DURING THE WELD, WHEN YOU

GET TO THAT POINT USE A SEPARATE, LOWER DATA WELD SCHEDULE.

IF YOU HAVE WELD START ISSUES, USE A HIGHER WIRE FEED RUN IN WELDSCHEDULE AT THE START.

E-mail from Deborah. Mr. Craig, I am in the process of preparing WPS's for weldingAluminum Bus ASTM B 236 gr 1350 .As AWS does not list this material in D1.2, nor doesthe ASME BPV Section II B I have purchased the Material Spec from ASTM Myquestion is in regards to the PQR Test requirements. D1.2 Table 3.4 calls for Tensilesand Side bends. Would the tensile property limits as set forth in B 236 for the materialbe the criteria for the weld tests ( PQR Record)? We will be welding 2" thick membersusing 1100 filler. Thanks Deborah Robinson

Ed's Answer: The 1100 filler is a good match for electrical conductivity, however you willget far better weldability and weld properties from a 4043 wire for your 1350 aluminumapplications. Irrespective of the weld wire used, as the part is 2 inches thick I would useMIG and use a 60 helium 40 argon mix As for the best weld process of course you canTIG weld with argon but to speed the job up consider high energy MIG spray transfer,

with 045 wire. As for the procedure set the wire in the spray mode, (data available in thissection) Remember with this applications it's all about attaining consistent weldpenetration. What ever process you use first pre-qualify the weld. You should weld asmall section and cut it and check the weld fusion profile attained. Regards Ed

Question: Ed when we liquid penetrant the "TIG" aluminum welds, in the heat affectedzone (HAZ), we sometimes see evidence of micro cracks. What can we we too preventthis?


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Ed's Answer. The micro cracks in the HAZ are frequently caused by excess weld heat(CURRENT) or by the High Frequency (HF) intensity. A reduction in either the GTAW weldcurrent, an increase in weld speed, or a reduction in the TIG, HF intensity should eliminatethe micro crack problems in the alum HAZ.


For optimum aluminum welds, focus on the above "optimum wire feed /amp" data.

For welding > 1/4 consider the 062 wire with traditional spray transfer. With regular spraytransfer travel speeds much greater than pulsed can be attained, >50 ipm are attainable.Also from a weld penetration and arc stability perspective spray can be superior to pulsed.

To improve weld fusion at arc starts consider these techniques. With manual MIG weldinguse a shorter wire stick out and a back hand technique for the weld starts. With a robot usehot start data, combined with back hand and a shorter WSO at the arc start.

If welding less than 3 mm, first choice would be the pulsedprocess, however short circuit can also be used.

If you use a spool gun orregular MIG gun and you don't know the wire feed settingyou are using, remember, it's important to always be awareof the wire feed rate. Check the wire feed rate by how muchwire comes from the gun in 10 seconds, then to make weld

parameter, wire feed adjustments, adjust the wire feed inincrements of 10%.

Use the optimum amps for the wire diameter selected. If you aresetting pulsed current, the typical opt pulsed range will be theoptimum amps minus approx. 30 - 60 amps.


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If welding aluminum vertical up with 0.046 wires and a traditional CVpower source set the vert up welds with a wire feed of 280 ipm (11o'clock traditional feeder) 140 amps 23 volts.

If welding short circuit set the weld volts between 14 and 17 volts.Listen to arc sound, if soft plop sound lower volts till crisp consistent

crackle sound, if harsh crackle with spatter increase weld volts tillcrisp consistent crackle sound.

Adjust the spray arc length with a voltage adjustment so the arclength is at its lowest and the weld transfers without disrupting theweld causing weld spatter. To lower the arc length lower the voltage.

ALUMINUM SPRAY TRANSFER, TYPICAL MIG WELD DATA:

WeldWire Size

SprayWire FeedRangeipm

SprayAmps

SprayVolts

Spray Parameters.

0.030 500-750 95-150 22-24

Amps 110 -130

Opt Wire feed500 - 675 ipm22 volts

0.035(1mm) 400-700

120-200 23-24Amps 150

Opt Wire feed500 ipm23 volts

0.046 (1.2mm) 285-600 140-270 23-25

Amps 170 -230

Opt Wire feed370 - 450 ipm24 volts

0.062 (1.6mm) 220-410 190-350 26-28

Amps 275

Opt Wire Feed300 ipm26/27 Volts.


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To set an optimum pulsed MIG weld start out with the very low end of the sprayrecommendations.

Note: Spray dataprovided will work as a start point for most alum wire grades. Forthose one pound spool guns with vague wire feed settings, measure the wire feedrate as it exits the gun. For alum welding application, if you don't know the spray orpulsed weld volts, start at 23 weld volts.

METRIC CONVERSION IPM WIRE FEED TO mm/sec x 0.42

ALUMINUM HOW MANY POUNDS OF MIG WIRE REQUIRED PER WELDSIZE?

Aluminum 1/8 3.2 mm fillet = 0.092 lb/ft 0.03 kg/m




Aluminum butt weld 13 mm plate 60 degree single V = 0.3 lb/ft 0.43kg/m

Aluminum butt weld 18 mm plate 60 degree single V = 0.4 lb/ft 0.66kg/m

Aluminum butt weld 25 mm plate 60 degree single V = 0.82 LB/FT 1.2kg/m


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Aluminum butt weld 38 mm plate 60 degree single V 1.7 lb/ft 2.6 kg/m

Aluminum butt weld 50 mm plate 60 degre single V 2.8 lb/ft 4.2 kg/m

ALUMINUM "ipm" FEED RATE TO WELD DEPOSITION RATE:

030 0.8 mmwire, ipm x 0.004 = lb/hr

035 0.9 mmwire, ipm x 0.0056 - l/hr

046 1.2mm wire, ipm x 0.0099 = lb/hr

052 1.4mm wire, ipm x 0.012 = lb/hr

062 1.6mm wire, ipm x 0.017 = lb/hr

093 2.4mm wire, ipm x 0.0415 = lb/hr.

ALUMINUM "m/min"FEED RATE TO WELD DEPOSITION RATE:

0.8mm wire, m/min x 0.07 = kg/hr

1 mm wire, m/min x 0.09 = kg/hr

1.2 mm wire, m/min x 0.16 = kg/hr




1990: A MESSAGE FROM ED TO THEMANUFACTURERS OF ALUM MIG WIRES

1990.For decades Aluminum wire manufacturers haveprovided 0.035 - 0.046 - 0.062 alum wires. If the majoraluminum weld wire manufacturers employed goodweld process control individuals and employed weld


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wire marketing managers that actully understood the weld issues that occur with aluminumMIG welds ,when the pulsed MIG process was introduced, they would have developed an0.052 (1.4mm) aluminum filler wire.

An 0.052 1.4 mm aluminum MIG wires would be ideal for many, robot, pulsed automotiveapplications which to day use the smaller 0.046 wires and have wire feed and burnbackissues. As with many of the MIG issues that face this industry, this is just another case ofprocess and application apathy / ignorance by the companies who make weldconsusmables. I wonder if there is an aluminum wire marketing person out that can finallyoffer the alum welding industry something that will actually provide practical weldingbenefits.

Aluminum Filler Metal Selection

ALUMINUM ALLOY

FILLER METAL SELECTION

AWS A5-10. Use first choice.Confirm choice with wiremanufacturer

Aluminum 2011 / 7075/ 7178Wrought Alloys

Welding notrecommended

Aluminum Casts - 242 / 520 /535 / 705 / 707 / 710 / 711 / 713/ 771

Welding notrecommended

Aluminum 1060 to 319- 333 -354 -355 - 380 Use 4145 or 4043

Aluminum 1060 to 413 - 443 -444 - 356 - 357 - 359 -

Use 4043 or 4047

Aluminum 1060 to 514 / 5454 /5154 / 5254 /

Use 4043 - 5183 - 5356

Aluminum 1060 to7005/7939/712/6070/5052/5652

Use 4043 - 4047

Aluminum 1060 to6061 / 6063 / 6101 /61516201/ 6951/

Use 4043 - 4047

Aluminum 1060 to 54565086 / 5083 Use 5356 - 4043

Aluminum 1060 to 50055050 / 1100 / 3003

Use 1100 - 4043

Aluminum 1060 to 3004 Use 4043

Aluminum 1060 to 1060 Use 1260 - 1060

Aluminum 1060 to 2014 / 2024 Use 4145

Aluminum 1100 and 3003 to Use 4145 - 4043


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319 - 333 354 - 355 - 380

Aluminum 1100 and 3003 to413 - 443 - 44 -356 - 357 - 359 -6067

Use 4043 - 4047

Aluminum 1100 and 3003 to

514 - 5545 - 5154- 5254 - 5052- 5652 Use 4043 - 5183

Aluminum 1100 and 3003 to6951

Use 4043 4047

Aluminum 1100 and 3003 to1060

Use 1260 - 4043

Aluminum 1100 and 3003 to5456 - 5086 - 5083

Use 5356 - 4043

Aluminum 1100 and 3003 to2014 - 2024 -2219

Use 4145

Aluminum 1100 and 3003 to5005 - 5050 - 3004

Use 4043 - 5183

Aluminum 1100 and 3003 to1100 -3003

Use 1100 - 4043

Aluminum 2014 and 2024 to319 - 33 -354 - 355 - 380

Use 4145 - 2319

Aluminum 2014 and 2024 to413 - 443 - 444 - 356 - 357 -359

Use 4145

Aluminum 2014 and 2024 to

6067- 6061 - 6063 -6101 - 6151-6201 -6951 Use 4145

Aluminum 2014 and 2024 to2219 - 2014 - 2024 -

Use 4145 - 2319

Aluminum 2090Use 2319 - 4047- 4145 Notelimited crack sensitivity

Aluminum 2219 to 319 - 333-354 - 355 - 380

Use 4145 - 2319

Aluminum 2219 to 413 - 443 -444 - 356 - 357 - 359 -

Use 4145 - 4043

Aluminum 2219 to 514 7005 -7939 - 712

Use 4043 - 4047

Aluminum 2219 to 6070 - 6063- 6101 - 6151 - 6201 - 6951

Use 4043 - 4145

Aluminum 2219 to 5456 - 5086-50835005 - 5050 3004

Use 4043

Aluminum 2219 to 5154 - 5254- 5052

Use 4043 - 4047


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5652

Aluminum 2219 to 2219 Use 2319

Aluminum 2519 - T87 to 2519- T87

Use 2319

Aluminum 2519- T87 to 5083H131

Use 4043

Aluminum 5005 - 5050 - 3004to 319333 - 354 - 355 - 380

Use 4043 - 4047

Aluminum 5005 - 5050 3004 to413 -443 - 444 - 356 - 357 - 359-

Use 4043 - 4047

Aluminum 5005 - 5050 3004 to514 - 5154 - 5254

Use 5654 - 5183

Aluminum 5005 - 5050 3004 to7005 - 7939 - 712 - 5083

Use 5356 - 5183

Aluminum 5005 - 5050 3004 to6070 - 5052 - 5652 - 5005 -3004 -

Use 4043 - 5183

Aluminum 5005 - 5050 - 3004 to 6061 -

6101 - 6063 - 6151 - 6201 -6951-Use 4043 - 5183

Aluminum 5005 - 5050 - 3004 to 5456 -5086 - 5083 -

Use 5356 - 5183

Aluminum 5005 - 5050 - 3004 to 5454 -5154 - 5254 -

Use 5654 - 5183

Aluminum 5005 - 5050 - 3004 to 3004 Use 4043 - 5183

Aluminum 5052 - 5652 to 319 - 333 - 354 -355 - 380

Use 4043 - 4047


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Aluminum 5052 - 5652 to 413 443 - 444 -456 - 357 - 359

Use 4043 - 5183

Aluminum 5052 - 5652 to 514 - 5454 - 5154- 5254 -

Use 5654 - 5183

Aluminum 5052 - 5652 to 7005 - 7039 - 712

- 5086 - 5083

Use 5356 - 5183

Aluminum 5052 - 5652 to 6070 5456 Use 5366 - 5188

Aluminum 5052 - 5652 to 6061 - 6063 -6101 - 6151 - 6201 - 6951

Use 5356 - 5183

Alum 5083Use 5556 -

5183

Aluminum 5083 to 413 - 443 - 440 - 356 -357 - 359 - 514 - 6070 - 5454

Use 5356 - 5183

Aluminum 5083 to 7005 - 7939 - 712 - 5456- 5083

Use 5183 - 5356

Aluminum 5083 to 6061 - 6063 - 6101 -6151

- 6201 -6951 Use 5356 - 5183Aluminum 5083 to 5154 - 5254 - 5086 Use 5356 - 5183

Aluminum 5083 to 5083 Use 5183 - 5356

Aluminum 5083 to 6070 Use 5356 - 5183

Alum 5086Use 5556 -

5183

Aluminum 5086 to 413 - 443 - 440 -356 -357 - 359

Use 5356 - 4043

Aluminum 5086 to 514 - 7005 - 7939 - 712 -6070 - 6061 - 6063 - 6101

Use 5356 - 5183

Aluminum 5086 to 6151 - 6201 - 6951- 5456- 5086

Use 5356 - 5183

Aluminum 5086 to 5454 - 5154 - 5254 - Use 5356 - 5183

Aluminum 5154 5254 5454 to 413 - 443 -444 - 356 - 357 - 359 -

Use 4043 - 5183

Aluminum 5154 5254 to 514 - 5454 - Use 5654 - 5183

Aluminum 5154 -5254 - 5454 to 700 - 7939 -712 - 6070 - 6061 -6063

Use 5356 - 5183

Aluminum 5154 -5254 - 5454 to 6101 - 6151- 6201 - 6951 - 5456 -

Use 5356 - 5183

Alum 5456 and 5383

Use 5556 -

5183

Aluminum 5454 to 5454 Use 5554 - 4043

Aluminum 6061 - 6063 - 6101 - 6201 -6151 -6951 to 319 - 333 - 354 - 355 - 380 -

Use 4145 - 4043

Aluminum 6061 - 6063 - 6101 - 6201 -6151 -6951 to 514 - 7005 - 7939 - 712

Use 5356 - 5183

Aluminum 6061 to 60XX Use 4043 - 5183


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Aluminum 7004 to 1060 - 1100 1350 - 3003-5052 - 5083 - 5086

Use 5356

Aluminum 7004 to 5454 - 6061 - 6063 -6351 -7004

Use 5356

Aluminum 7005 - 7039 - 712 - to 319 - 333 -

3544 - 355 - 380 - 413 - 443 - 444 - 356-79 -

Use 4043

Aluminum 7005 - 7039 - 712 to 514 Use 5356

Aluminum 7005 - 7039 - 712 to 7005 7939 -712

Use 5039

Aluminum 514 to 413- 443- 444 - 356 - 357 -359

Use 4043 5183

Aluminum 514 to 514 Use 5654 - 5183

Aluminum 413 - 443 - 444 - 356 - to 319 -333 - 354 - 355 - 380

Use 4145 - 4043

Aluminum 413 - 443 - 444 - 356 to 413 443 -4444 - 356 - 357 - 359

Use 4043 orsame as base

Aluminum 356 - 357 - 359 - to 319 - 333 -354 - 355 - 380

Use 4145 orsame as base

6061-T6 Aluminum Weld Questions:

Question: We weld 6061-T6, with 4043 wire. While trying to establish the weld procedurequalification for a groove weld, we have been unable to attain the minimum tensile strength

as required by the 97 AWS structural weld code DI.2-97. The weld integrity appears fine,however the transverse tension tests are failing in the HAZ, at unacceptable, AWS specifiedstrength loads.

Ed's reply:This is a common problem with the heat treatable 6xxx alloys. The lack ofacceptable strength in this heat treated aluminum alloy is usually caused by "weldoverheating" of the base metal. 6061-T6 gets its strength through solution heat treatmentand is also artificially aged. This aluminum alloy is heated to 990F, which dissolves the alloyelements magnesium and silicon into magnesium sillicide into a super saturated solution.Quenching in water follows to trap the resulting elements in a supersaturated solution. Thematerial is then reheated in the 300F range and held for a predetermined time, (this is aging).The aging is carried out to precipitate some of the compounds / elements out of thesupersaturated state to improve the mechanical properties. The 6061-T6 alloy in the

unwelded condition will have an approx. tensile strength of approximately 45 ksi.Weldingdisturbs the carefully controlled heat treatment and the 6061-T6 minimum tensile is reducedto approx. 24 ksi. When welding, multi-pass welds or high weld heat can dramatically lowerthe aluminum tensile strength. When welding the 6061 T6 alloys with either 4xxx or 5xxxfiller metals, to meet the code, minimum tensile strength requirements, ensure you complywith the "minimum" base metal thickness requirements, its beneficial to use a thicker plateas this provides a greater heat sink for the weld qualification test. Ensure compliance withthe heat treatment and holding time. For info go to the AWS Structural Weld Code.


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WELDING 6061-T6, THINK HEAT REDUCTION:* The MAX preheat and "interpass temp" is 250F, do not weld on this part till thetemp is below 200F. * If possible if using fixtures, give consideration to copper componentsthat can be attached near the weld to act as a "heat sink".

* When MIG welding use the highest possible weld travel rates with the lowest possible weldvoltage.

* Use stringer beads rather than weaves, the weld speed will be quicker with stringers.

* Do not use helium in the gas mix, unless it's essential. .

6061-T6 WELDS AND HEAT.If welding with 6061-T6, and the parts are subject to heat consider 5554 / 4047 / 4043 filler. If5356 / 5556 or 5183 is used sensitization of magnesium in the metals can result in stresscorrosion or part failure.

6061-T6 WELDS AND COLOR.If welding with 6061-T6 and this wire is used on parts that require good color match afteranodizing. Consider 5356. MIG wires 4XXX would after anodizing produce grayish lookingwelds.

6061-T6 WELDS / STRENGTH and POST WELD HEAT TREATMENT.If using this 6061-T6 filler metals to weld critical applications and applications that havemulti-pass or extensive welds in a localized zone, its likely you will require a post weldsolution heat treatment and artificial aging in order to restore the application strength in theweld proximity and return the application to the -T6 temper properties. With applicationssuch as this its logical to be concerned about the weld wire selection and mechanicalstrength of the "weld" after post weld heat treatment. Remember that the 5183 - 5356 -5556filler alloys are non-heat treatable alloys which can undergo negative changes whensubjected to heat treatment. The 4043 filler alloy, is also non-heat treatable, however when

this weld has dilution with the base metal the resulting weld properties can respond to theheat treatment. Consider for post heat treat applications using the 4643 MIG or TIG wires, asthese weld consumables are heat treatable and can provide a weld of comparable strengthto that of the base material.

6061 WELDS AND CRATER CRACKING.To reduce crater cracking with 6061 alloys try welding with 4047 which in contrast to 4043,the 4047 weld wire freezes more quickly reducing the potential for hot cracking. Alsoconsider weld equipment that provides a good crater fill program.

6063-T6 TIG Weld Question.Ed, we pulsed TIG weld 6063-T6 electronic cabinets. We weld the boxes in the inside and

outside edges and are experience weld cracking. If required we weld with 4043 filler,however when welding the outside welds we use no filler. How can we reduce the weldcracks.

Ed's reply.The aluminum magnesium silicon 6xxx alloys are crack sensitive due to themagnesium silicide. The best way to reduce the TIG weld cracking sensitivity with 6xxxalloys is to use filler metal. The filler metal will dilute the weld with the magnesium if 5xxxfiller is used , or with silicon if 4xxx filler metals are utilized. If MIG welding use vee preps orlarge throat fillet welds to ensure that sufficient weld filler metal is used.


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T6 / 6063 - T52 MIG Weld Question.Ed, When welding 6063-T6 to 6063-T52 which alloy will give the best strength. I believe that4043 has the least crack sensitivity but the lowest strength, however I don't know thedifference between 5356 and 5556. I need to have the best as-welded strength for minimumfillet sizes.

Ed's reply.For butt welds the 4043 and 5556 provide similar results. When using these wiresand welding butt weld on the alloys discussed you would expect the parts to fail in the HAZrather than in the welds. For fillet welds on these aluminum alloys go with the 5356 wire, itwill provide the strongest fillet welds.

2008: Question: Ed we are TIG welding a 6061 fabrication the part are 1/8 to 3/8. Most of thewelds are are made with a 5356 wire with the TIG process. The distortions on the fixtured,clamped parts can be from from 1/16 to 1/4. We are considering changing to pulsed MIGPROCESS DO YOU SEE THIS AS A SOLUTION. Thanks. Frank Givens.

Welding 6061 with MIG or four times slower with TIG andBELIEVE IT OR NOT, THE WELD DISTORTION WILL BE SIMILAR.


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Ed's Answer to the 6061weld distortion question. There are a number of issues going on onwith your application.Think about what that high strength 5053 fillet weld does to that much lower strength, 6 mm,6061, 6 mm metal during the 5356 weld shrinkage and solidification stage.

I firmly believed that if I used the pulsed MIG process that welds four times faster than theTIG process, that irrespective of the metal or filler metal utilized, the end result had to beless weld distortion. Then I put the weld helmet on and welded the above parts and mytheory was shot to pieces. I tacked some parts on one side and other parts both sides.Before welding the vertical parts was set with a square. I then made 4, two inch stitch weldswith the pulsed MIG process on one part and the TIG process was used on the other part forcomparison.The results led to the conclusion that the amount of weld heat or the weld heat time reallydid not matter?


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Also on these parts to minimize hot cracking and reduce weld distortion, I would use thepulsed MIG process and 4043 filler metal with straight argon. As to minimizing distortion youwill need to use more braces and offset and possibly pre-bend part to compensate and letsface it, with the time saved from the MIG process, you can use that time to get the bighammer out and do what many welders do best.

After welding with TIG and MIG, the weld distortion was the sameon both the tacked and none tacked parts

6061 AFTER WELDED WITH TIG and MIG 5053.

Data on Aluminum Alloys

Welding is not recommended on alum casts 242 - 520 - 535 -705 - 707 - 710 - 711 - 713 - 771, Check filler recommendationsat the bottom of this site with alum wire manufacturer toensure color match, crack resistance, strength, ductility, or


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corrosion resistance. Also clarify if heat treatment required.

None Heat Treatableare used in the strain hardened (WORKHARDENED) condition to improve the alloys mechanicalproperties. While welding, the weld heat will return the HAZ to itsannealed condition. This condition typically reduces the strength

in the HAZ area.

Heat Treatablealum alloys are often in the T-4 or T-6 condition,solution heat treated and naturally aged, or solution heat treatedand artificially aged. These metals after heat treat provideoptimum mechanical properties. Weld heat (time andtemperature) will change these properties. Typically the result ofa weld is a partial anneal and an overaging affect.

The bottom line, the reduction in mechanical properties of theheat treated alum alloys is greatly affected by the "time andtemp" of the weld. Minimum preheat, low weld parameters, weldsmade at high speeds, stringer rather than weaves, along with low

weld interpass temperatures can minimize the heat effects,however you will experience a considerable loss in the tensileproperties in the HAZ adjacent the weld.

1XXX Series Aluminum Alloys Min 99% Aluminum. None HeatTreatable. Ultimate tensile 10 - 27 ksi. Selected for superiorcorrosion resistance. Typically welded with matching alloy or4xxx filler.

Alloy DesignationAlloy Content /

Description

1XXX99% minalum. NoneHeat Treat.

1050

UNS A91050ASTM B 491UNI 4507

Italy P-ALP99.5

USA/UK/Japan/ISO/Germany = Al 99.5

99.5% Alum

1050-H16

Tensile 19 ksi 130

MPaYield 18ksi 125 MPa

1060

UNS A91060ASTM B209SAE J454AMS 4000

99.6% AlumMelts 1195F

1060-H14 Tensile 14 ksi


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Yield 13 ksi

1100

UNS A91100AMS 4001ASTM B209SAE J454

ISO/GermanyAL99.0

99% Alum + 0.12 CuMelts 1190FThis series used forcooking containers

food and chemicalhandling

1100-H16Tensile 21 ksi

Yield 20 ksi

1100-OTensile 13 ksi

Yield 5 ksi

1XXX AND 3XXX WELDED WITH ER1XXX POTENTIALFOR EXCESS POROSITY ON COMPONENTS > 6 mmCONSIDER 60 HELIUM 40 ARGON

2XXX Aluminum Alloys Aluminum Copper, Heat

Treatable.Ultimate Tensile Strength 27 to 62 ksi. High strengthhigh performance alloys often used in aero space. Some arenone weldable as susceptibility to hot cracking or stresscorrosion cracking. For the weldable grades these are typicallywelded with high strength 2xxx filler metals, or 4xxx

2011welding not

recommended

2014

Germany AlCuSiMnItaly P-AlCu4.4Si/Mn/MgUNI 3581

93.5% AlumSi 0.8Cu 4.4 - Mn 0.8 - Mg0.5Melts 950F - 510C

2014 -OTensile 27ksi

Yield 14 ksi

2014- T4

T-4 or T-6=solution heat

treated andnaturally aged orsolution heattreated andartifically aged.Weldiing theT-4-6 parts effectsthe mechanical

Tensile 62 ksiYield 42 ksi


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properties.Typically an annealand overage effectreducing tensilestrength especially

in HAZ.To minimizeerffectslow preheats andlow interpass temp

2024

UNS A92024AMS 4007SAE J454Germany AlCuMg2Ittaly PAlCu4.5MnUNI 3583

93.5 Aluminum -Cu4.4Mg 1.5 - Mn 0.6Melts 935F 500CHigher strength

than 1XXXUsed for Aircraftcomponent,hardware, rivets,wheels etc.NOTE NOTWELDABLEif weld susceptableto stress corrosioncracking afterwelding that can

cause delayedfailures.

2024-T4 -T351


2024 - O

Tensile 27 ksiYield 11 ksi As thisalloy contains asmall amount of Mg

the hot crackingpotential in thegrain boundary areais increased. Uselowest heat inputavoid mult-passwelds.

2036 UNS A92036 96.7 Aluminum


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Cu 2.6 - Mg 0.45 -Mn 0.25Melts 1030F

2036 - T4Tensile 49 ksi

Yield 28 ksi

2048

94.8 Alum - Cu 3.3 -Mn 0.4Mg 1.5Tensile 66 ksi 455MPa

Yield 60 ksi

2090Li 1.9 - 2.6 - Cu 2.4 -30Zr 0.08 - 0.15

2219

93 Aluminum

Cu 6.3 - Mn 0.3 Ti-V-ZrMelt range 1010 -1190F543 - 620C. With theCu above 4.5% hotcracking snsitivitydecreased

2219-T81Tensile 66 ksi

Yield 51 ksi

2219-O Tensile 25 ksiYield 11 ksi

2219-31-351Tensile 52 ksi

Yield 36 ksi

3XXX Aluminum Series Aluminum - Manganese.

None Heat Treatable Ultimate Tensile 16 to 41 ksi. Moderatestrength, good corrosion resistance, good for high temp use.Typically welded with 1xxx - 4xxx - 5xxx

3003Germany AlMnCuUNI 7788Italy P-AlMn1.2Cu

98.6 Alum - Cu 0.12- Mn 1.2Good Forming


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Good WeldabilityUsed For FoodHandlingAir conditioning orheat

exchangers.Melt 1190F


Yield 6 ksi


Yield 21 ksi


Yield 27 ksi

3004

Germany

AlMn1Mg1Italy PAlMn1.2Mg

97.8 AluminumMn 1.2 - Mg 1

Melt Range 1165 -1205F630 - 650C


Yield 10 ksi

3004 - H34Tensile 35 ksi

Yield 29 ksi

Weld Note: POTENTIAL FOR EXCESS POROSITY ONCOMPONENTS > 6 mm CONSIDER 60 HELIUM 40ARGON

4XXX Aluminum Series Aluminum - Silicon,

Heat Treatable and None Heat Treatable. Ultimate tensile strength25 - 55 ksi. Silicon reduces lower melting temp, improves fluidity,often used for weld electrodes. If the 4xxx contains magnesiumor copper instead of silicon these alloy are usually heat treatableand used when the welds will be subject to post weld heat treat.

4032

85% Aluminum

Si 12.2 - Cu 0.9Mg 1.0 Ni 0.9

4032-T6 UNS A994032

Tensile 55 ksi 380MPa

Yield 46 ksi 315MPa


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5XXX Aluminum Aluminum - Magnesium range0.2 to 6.2%.

None Heat Treatable. Ultimate tensile strength 18-51 ksi. These

readily weldable alloys have the highest strength of the none heattreatable alum alloys.

5005Italy PAlMg0.8UNI 5764 - 66

99.2 Aluminum - Mg0.8Melt 1170FSimilar to 3003


Yield 25 ksi


Yield 6 ksi

5050

98.6 Aluminum - Mg1.4Used for ApplianceTrim,Auto oil and gaslinesMelt Temp 1155 -

1205F620 - 650C


Yield 24 ksi


Yield 8 ksi

5052

Germany AlMg2.5Italy P AlMg2.5

A low strength alumalloy

97.2 Aluminum - Mg2.5-Cr 0.25Melt Range 1125 -1200F

605 - 650CAir Conditioners,Heat Exchangers,Aircraft Fuel Lines,Fuel Tanks StreetLights, Appliances


Yield 13 ksi


27/34


Yield 31 ksi

5056

UNS A95056Germany AlMg5

Italy P-AlMg5UNI 3576

95.5 Aluminum - Mg5Mn 0.12 - Cr 0.12

Wire products,Screens


Yield 13 ksi

5056 -OTensile 42 ksi

Yield 22 ksi

5083- 5 Mg is the highest strength non-heat-treatable alloy incommercial use. 5083 provides good formability and weldability.5083 has excellent tensile strength in the weld zone as a result of

its as-rolled properties. 5083 is used for ships hulls and theconstruction of tactical military vehicles. 5083 is also used inhighly stressed welded assemblies, cryogenic vessels, dumptruck boxes and storage tanks.5083 has excellent resistance tocorrosion.

5086

UNS A95086Germany AlMg4MnItaly P AlMg4.4UNI 5452-64

95.4 Aluminum - Mg4.0Mn 0.4 - Cr 0.15Melt 1085F. Used

formedium strengthapplications,marine tanks,trucks. This alloyhas goodweldability and ismore formable thanalloy 5083. As thisalloy is resistant tostress corrosion

cracking andexfoliation, it alsohas wideapplication in themarine industry.Corrosionresistance isexcellent.


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Yield 17 ksi

5086 - H32-116 0 117


5154 Germany AlMg3.5

96.2 Aluminum Mg3.5-Cr 0.25Melt 1100Tanks, trailers,trucks, pressurevessels


Yield 17 ksi


Yield 36 ksi

5454

GermanyAlMg2.7MnItaly P-AlMg2.7Mn

High strength alumalloy with elevatedtemp applications

96.3 Aluminum Mg2.7Mn 0.8 Cr 0.12Car wheelsSuitable fortemperatureapplications due tolimit on Mg


Yield 17 ksi

5454-H36

Tensile 49 ksiYield 40 ksiMelt Range 1115F -1195F600 - 650C

5456 UNS A95456

93.9 Aluminum Mn0.8Cr 0.12 - Mg 5.1Medium strength

truck, structuraland marine.Melt 1055F

5456 - OTensile 45 ksi

Yield 23 ksi


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5456-H321-116


5457

98.7 Aluminum Mg0.3 Mn 0.3

Melt range 1165-1210F630 - 655 C


Yield 6 ksi

5457 -H25Tensile 19 ksi

Yield 7 ksi


Yield 27 ksi

Metric Conversion of Filler Strength. ksi x 6.894 = MPa

AluminumAlloy

DesignationAlloy Content /Description

565297.2 Mg 2.5 - Cr 0.25Melt range 1125 1200F605 - 650C

5652 - OTensile 28 ksi

Yield 13 ksi

5652-H32

Tensile 33 ksi

Yield 28 ksi

5652- H34Tensile 38 ksi

Yield 31 ksi

5657 99.2 Aluminum Mg 0.8Melt 1175F


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5657- H-28-38Tensile 28 ksi

Yield 24 ksi

5657- H25Tensile 23 ksi

Yield 20 ksi

6XXX Aluminum Series Aluminum Magnesium Silicon,(magnesium silicides for heat treatment).

Ultimate tensile 18 - 58 ksi. Fabtication, Extrusions. These alloysare solidification crack sensitive, dont weld without filler metal.Typically welded with 4xxx and 5xxx

6005 GermanyAlMgSi0.7

98.7 Aluminum Si 0.8 Mg0.5


Yield 15 ksi


Yield 35 ksi

6351 97.8 Aluminum Si 1.0Mn 0.6 Mg 0.6

6351 - T4

Tensile 36 ksi

Yield 22 ksi


Yield 41 ksi

6061

GermanyAlMgSiCu

UNI 6170-68Italy P -AlMg1SiCu

98.5 Aluminum Si 0.7Mg 0.8

6061 is a heat-treatablegrade widely used inlight to medium strength

structural applications.such as aircraft, marine,furniture,air conditioning andheat exchangercomponents.Thesealloys have goodcorrosion resistance


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and weldability andpossesses goodformability in the 0 to T4tempers.

6061 loses appreciablestrength when weldedand it is replaced by the5000 series alloys whereafterweld strength is aprime consideration.

6XXX IS OFTEN MANUFACTURED AS EXTRUDEDCOMPONENTS


Yield 8 ksi

6061-T6-651Tensile 45 ksi

Yield 40 ksi

6061-T4-451 UNS A96061Tensile 35 ksi

Yield 21 ksi

606398.9 Aluminum Si 0.4 Mg0.7Tube, pipe, hardware

6063-O Tensile 13 ksiYield 7 ksi


Yield 31 ksi

606695.7 Aluminum Si1.4Cu 1 - Mn0.8 Mg 1.1


Yield 12 ksi

6066-T4-451Tensile 52 ksi

Yield 30 ksi

6070 96.8 Aluminum Si 1.4Cu 0.28 Mn 0.7 Mg 0.8


Yield 10 ksi


Yield 20 ksi


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615198.2 Aluminum Si 0.9Mg0.6 - Cr 0.25Forgings auto parts

6151-T6

Tensile 32 ksi

Yield 28 ksi

6205

98.4 Aluminum Si 0.8Mn 0.1Mg 0.5 - Cr 0.1Zr 0.1


Yield 20 ksi


Yield 42 ksi

626296.8 Aluminum Si 0.6 Cu0.28. Mg 1- Cr 0.09 - Bi0.6 - Pb 0.6


Yield 55 ksi

635197.8 Aluminum Si 1.0Mn Mg 0.6

6351-T4

Tensile 36 ksi

Yield 22 ksi

646398.9 Aluminum Si 0.4Mg 0.7


Yield 13 ksi

7XXX Aluminum Aluminum Zinc. Heat Treatable.

Ultimate tensile strength 32 - 88 ksi.Provide the highest strength aluminum alloys aircraft, auto, sportsequipment. Some weldable some unweldable. Often welded with5xxx alloys.

7005 Al - Zn - Mg


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alloys 93.5 Aluminum Mn 0.45-Mg1.4 Cr 0.13- Zn 4.5 - Ti0.04- Zr0.14.

Resists hot cracking

better thanAl - Zn - Mg - Cu alloyssuch as 7075. Usuallywelded with 5356enough magnesium toprevent cracking. Avoid4043 as the Si can makethe welds brittle.

7005-O

Tensile 28 ksi

Yield 12 ksi


Yield 50 ksi

7075

GermanyAlZnMgCu1.5Italy P -AlZn5.8MgCuUNI 3735

90 Aluminum Cu 1.6 Mg2.5 Cr 0.23 Zn 5.6High sttrength Aircraftand structuralMelt 890 - 1175FUnweldable, if welded

stress corrosion crackscan occur, (delayedcracking potential)


Yield 15 ksi

7075-T6 T651Tensile 83 ksi

Yield 73 ksi

7178welding notrecommended on thiswrought alloy

7475 90.3 Aluminum Si 1.5 Mg2.3 Cr 0.22 Zn 5.7


Yield 67 ksi

Warning: To avoid cracks. Mixing alloys as typically occurs in welding dissimilar


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aluminum alloys can increase the crack sensitivity. When selecting the aluminum fillermetal, examine the base alloy and filler alloy combination and avoid a final mix of alloyshigh in both Mg and Cu content.

ALUMINUM 5xxx SERIES AND STRESS CORROSION (SS) CRACKING:

Question: Ed what is stress corrosion cracking and how does it effect the 5xxx seriesaluminum grades?

Answer: Stress corrosion cracking and part failure can occur from an accelerated formof corrosion material in an application subject to tensile stresses. The alum alloyssubject to this form of corrosion are

2xxx series.5xxxx series that contain more than 3% magnesium.7xxx series.

The 5xxx series of alum has a magnesium content of 1 to 5%. The common 5 xxx seriesalloys with > 3% magnesium which have been work hardened, can be sensitive to grainboundary precipitation in select locations. The precipitation typically can occur if theapplication is held at prolonged periods at moderate temperatures typically between 150and 350F. In this temp range precipitate can form that are anodic to the alummagnesium matrix leading to the corrosion issues. At temperatures above the 350F, thegrain boundary changes shape and reduces the potential for the formation of SCC. Thebottom line, the 5xxx alloys with > 3% magnesium should not be used for elevatedtemperature applications.

It's important to note that there are specific 5xxxx alloys designed specifically forelevated temp applications. Alloys such as 5454 welded with 5554 have 2 to 3%magnesium making the suited to elevated temp applications.

DID YOU VISIT THE GAS SECTION TO READABOUT OZONE FORMATION AND ALUM WELDS?
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