Quantitative Investigation of Heat-Affected

Zone Cracking in Aluminum Alloy A6061

Grain size, solidus temperature and concentrations of Si and

Mg were studied as factors influencing HAZ cracking

BY M. MIYAZAKI, K. NISHIO, M. KATOH, S. MUKAE AND H. W. KERR

ABSTRACT. The influences of several fac- using GMA welding. He reported that of a crack: 1) thermal factor, heat neces-
tors on heat-affected zone cracking of cracks could be developed due to the in- sary to melt grain boundaries; 2) metallur-
aluminum Alloy A6061 were investigated. vasion of low-melting compounds and/or gical factor, crack susceptibility of a mate-
First, the influence of the grain size on the the diffusion of Mg and Si from the weld rial; and 3) mechanical factor, force or
weld heat-affected zone cracking of GTA metal along grain boundaries in the HAZ deformation necessary to open grain
spot welds on A6061 was studied using a (Ref. 1). boundaries.
Varestraint test. The maximum crack Moreover, Gittos, ef ai, performed a There are still many factors which have
length increased when the grain size was study using the Patch test, and reported not yet been investigated in detail. The
increased from 0.05 to 2 mm, but in- that longitudinal cracking was developed present investigation was made first on
creased more gradually for further in- when the solidus temperature of the weld the influence of the grain size using a
creases in grain size. The influences of metal was higher than that of the base Varestraint test when GTA welding was
solidus temperature and penetration of metal (Ref. 2). These results are all qualita- performed. The influences of solidus tem-
alloying elements from the weld metal tive. Katoh and Kerr have performed a perature and penetration of alloying ele-
into the HAZ were investigated for GMA quantitative study on Al-Mg-Si alloys using ments from weld metal into the HAZ were
welds. For dilutions between 20 and 80%, the Varestraint test (Refs. 3, 4). The main also investigated.
for both 5356 and 4043 filler metals, the results obtained are as follows: liquation
solidus temperature was increased by Si, cracks were developed in the HAZ of the Materials Used and Experimental
but decreased by Mg. Generally, the soli- weld metal with GTA welding, and both
dus was higher in the case of 5356 filler Procedures
augmented strain and heat input larger
metal. Longitudinal cracking was devel- than critical values were necessary for the Table 1 shows the chemical composi-
oped along the fusion boundary only in cracks to be developed. In the case of an tions of the materials used. Commercial
the case of 5356 filler metal. This phe- extruded material in which the grain size A6061-0 alloy, which was obtained by
nomenon was explained using the relation was larger than in the case of a rolled ma- annealing A6061-T6 listed in Table 1, was
between the solidus temperature and the terial, the crack length tended to become used to investigate the influence of grain
heat input. Transverse cracking was ob- longer even for the same heat input and size, and the commercial A6061-T6 alloy
served for the welded condition using augmented strain. The crack susceptibility was used to examine other aspects. Di-
4043 filler metal, but in the case of 5356 in GTA welding was decreased by alloying mensions of the test specimens were 6
filler metal, subsurface cracks developed, elements such as Cr, Mn and Cu, but was mm (0.24 in.) thick, 50 mm (2 in.) wide and
and were observed only after machining- increased by M g and Si. With GMA weld- 110 mm (4.3 in.) long.
off the reinforcement. High concentra- ing, both longitudinal and transverse Grain sizes of the base metal were
tions of Si and Mg were observed near cracks were developed in the HAZ when changed using the strain-annealing
cracks in the case of 4043 and 5356 filler 5356 filler metal was used. Only trans- method. That is, the base metals were
metals, respectively. This indicates that verse cracks were developed when 4043 annealed in air for 15 h at 590°C (1094°F)
penetration of these elements affects the filler metal was used. Generalizing these after being tensile strained between 2 and
transverse cracking. results, it is considered that the following 30%. The largest average grain size of
three factors will affect the development about 9 mm (0.35 in.) was obtained in the
Introduction case of tensile strain of about 4%. When
tensile strains were larger than 4%, aver-
Al-Mg-Si alloys have been widely used age grain sizes decreased hyperbolicly
in welded structures. Anticorrosion treat- with increases in tensile strain. An average
KEY W O R D S
ment is almost unnecessary for these grain size of about 0.5 mm (0.02 in.) was
alloys even near a beach, because they Aluminum Alloy A6061 obtained for a tensile strain of 20%. Little
have good corrosion resistance. The proof A6061 HAZ Cracking coarsening of grain size was obtained for
stress of A6061-T6 is defined to be more Quantitative Study
than 250 MPa (36 ksi); almost the same as 5356 Filler Metal
the yield stress of a mild steel. These alloys 4043 Filler Metal
Effect of Mg Addition M. MIYAZAKI, K. NISHIO, M. KATOH and S.
have, however, higher crack susceptibili- MUKAE are with the Department of Materials
ties than mild steel in the weld heat- Effect of Si Addition
Solidus Temp. Effect Science and Engineering, Kyushu Institute of
affected zone. Technology, Kitakyushu, lapan. H. W. KERR is
Liquation Cracking
Previous work has been reported con- with the Department of Mechanical Engineer-
GTA Spot/GMA Welding ing, University of Waterloo, Waterloo, Onta-
cerning this HAZ cracking. For example,
Tsujimoto, et al., has performed studies rio, Canada.

362-s I SEPTEMBER 1990

 FORCE

WELDING DIRECTION SPECIMEN

yCRACK
1f
(CCC(CCC) i n't BENDING
BLOCK

(a)
Fig. 1 —Schematic representation of a Varestraint test. tb]

tensile strains less than 4 % , f o r w h i c h t h e

Table 1—Chemical Compositions of Materials Used (wt-%)
average grain sizes w e r e b e t w e e n 0.05
m m (0.002 in.) a n d 0.2 m m (0.008 in.) (the
Si Cu Fe Mg Mn Zn Cr Ti
grain size o f t h e base metal o f A 6 0 6 1 - 0
b e i n g a b o u t 0.05 m m ) . Commercial 6061-T6 0.550 0.170 0.264 0.890 0.018 0.010 0.105 0.038
4043 filler metal 4.770 0.006 0.100 0.010 0.030 0.007 0.037 0.041
T h e susceptibility t o liquation cracking
5356 filler metal 0.020 0.008 0.088 4.880 0.058 0.005 0.053 0.075
w a s e v a l u a t e d b y the m a x i m u m crack
length that w a s o b s e r v e d in t h e H A Z
w h e n a Varestraint test w a s p e r f o r m e d .
Study of G T A W e l d s sult w h e n t h e r e w e r e parallel lamellar
Figure 1 s h o w s a schematic representation
grain boundaries in t h e d i r e c t i o n of 0 = 0
of a Varestraint test. G T A spot w e l d i n g
Relation between Grain Boundaries and d e g . Cracks w e r e o b s e r v e d along these
w a s p e r f o r m e d f o r the study o n t h e influ-
Features of Cracks grain b o u n d a r i e s . T h e same o r i e n t a t i o n of
e n c e o f grain size, a n d G M A w e l d i n g w a s
cracks, n o r m a l t o t h e m a x i m u m tensile
p e r f o r m e d f o r the others. In o r d e r t o Figures 2 A - C schematically s h o w cracks
strain, w a s o b s e r v e d e v e n in t h e direction
change t h e a u g m e n t e d strain, seven b e n d - that w e r e o b s e r v e d in t h e H A Z w h e n G T A
of 9 being nearly 9 0 d e g , w h e r e n o crack
ing blocks w e r e e m p l o y e d having radii R s p o t w e l d i n g w a s p e r f o r m e d o n t h e T6
w a s o b s e r v e d in t h e case o f the base
b e t w e e n 75 m m (3 in.) a n d 1000 m m (39 base metal a n d annealed materials w i t h
metal. As s h o w n in Fig. 2 C , the crack
in.). T h e a u g m e n t e d strain e w a s o b t a i n e d coarse grains. Figure 2 A w a s t h e result f o r
length increased f r o m 9 = 0 t o 9 = 9 0
using Equation 1: t h e base m e t a l , in w h i c h cracks w e r e d e -
d e g in this case, since t h e c o n t o u r o f each
v e l o p e d radially in t h e H A Z . T h e crack
t = t/2R crack e n d a n d t h e fusion b o u n d a r y o f t h e
(I) length w a s t h e longest in t h e d i r e c t i o n o f
w e l d metal w e r e nearly in a concentric
w h e r e t is t h e thickness o f t h e s p e c i m e n . 0 = 0 d e g a n d decreased w i t h an increase
c o n f i g u r a t i o n as indicated b y t h e thin solid
A r a m s p e e d o f 35.3 m m / s (1.4 in./s) w a s in theta as indicated in Fig. 2A (Ref. 4). Fig-
line in this figure. This p h e n o m e n o n sup-
used f o r this investigation because little u r e 2B w a s t h e result in coarse-grained
ports t h e result that t h e liquation-cracked
d i f f e r e n c e in t h e crack length w a s o b - material w h e n there w e r e t w o grain
region has a close relation w i t h t h e max-
s e r v e d w h e n preliminary tests w e r e per- b o u n d a r i e s near the w e l d m e t a l ; cracks
i m u m t e m p e r a t u r e in t h e H A Z , t o b e dis-
f o r m e d using ram speeds o f 22.4, 3 0 . 0 p r o p a g a t e d along these grain boundaries.
cussed later.
a n d 35.3 m m / s (0.9, 1.2 a n d 1.4 in./s). Thus, t h e cracks o b s e r v e d h e r e w e r e i n -
tergranular. T h e r e f o r e , w h e n t h e r e w a s
G T A s p o t w e l d i n g w a s p e r f o r m e d in
n o grain b o u n d a r y , n o crack w a s o b - Influence of Grain Size on the Maximum
the center o f a specimen u n d e r t h e c o n -
served e v e n in t h e d i r e c t i o n o f 9 = 0 d e g , Crack Length
ditions o f w e l d i n g current I = 120 A, arc
w h i c h is t h e easiest d i r e c t i o n f o r t h e cracks Figure 3 s h o w s t h e relation b e t w e e n
v o l t a g e E = 25 ~ 2 8 V a n d arc time t =
t o d e v e l o p (Ref. 4). Figure 2C w a s the r e - the m a x i m u m crack length a n d grain size
20 s (DCEP). T h e conditions o f G M A
w e l d i n g w e r e I = 140 A a n d E = 2 1 ~ 2 3
V . W e l d i n g heat inputs w e r e c h a n g e d b y
changing w e l d i n g speeds b e t w e e n 2 0 0
a n d 1300 m m / m i n (8 a n d 5 1 i n . / m i n ) .
W h e n p e r f o r m i n g a Varestraint test, b e a d -
o n - p l a t e w e l d s w e r e d e p o s i t e d along t h e
centerline o f t h e s p e c i m e n in t h e longitu-
dinal d i r e c t i o n . T h e specimen w a s b e n t
a p p r o x i m a t e l y o n e s e c o n d b e f o r e the arc
for the welding was stopped.
T h e crack lengths w e r e m e a s u r e d using
a p r o j e c t o r ( 2 0 X ) o r a magnifying glass
e y e p i e c e (the m i n i m u m scale: 0.1 m m ) in
the a s - w e l d e d c o n d i t i o n in t h e case o f
G T A spot w e l d i n g . For G M A w e l d s , t h e
lengths o f t h e longitudinal a n d transverse ta) lb) (c)

cracks w e r e measured after t h e r e i n f o r c e - Fig. 2 - Schematic representation of HAZ cracking. A—In the case of base metal; B — in the case of
m e n t w a s r e m o v e d b y machining. having two grain boundaries; C-in the case of having lamellar grain boundaries.

WELDING RESEARCH SUPPLEMENT 1363-s

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AVERAGE GRAIN S I Z E , d (mm) DISTANCE FROM FUSION BOUNDARY, x (mm)
F/g. 3 — Relation between the maximum crack length and a verage grain Fig. 4 — Relation between the distance from the fusion boundary into
size (( = 3.0%). HAZ and the maximum temperature.

d for a fixed augmented strain. The max-

imum crack length (the maximum radial
distance of cracking from the fusion
boundary) increased greatly for grain sizes
between 0.05 and 2 mm (0.002 and 0.08
in.), but increased more gradually with
further increases in the grain size above 2
mm. The maximum crack length reached
up to 4.5 mm (0.2 in.) when the grain size
was 8.8 mm (0.35 in.). Figure 4 shows the
relation between the distance from the
fusion boundary into the HAZ and the
maximum temperature, as measured by
temperature-indicating lacquers. The re-
lation between the grain size effect and
the maximum temperature of cracking is
shown in Fig. 5, which can be obtained by
combining Figs. 3 and 4. In the case of the
base metal, the maximum temperature
was 600°C (1112°F) at the crack tip. This
is almost the same as the measured solidus
temperature (597°C/1107°F) of the base
metal. When the grain size became larger,
the maximum temperature at the crack tip
gradually decreased and cracks were ob-
served even at temperatures much lower
than the solidus temperature of the base
metal. For the largest grain size studied,
8.8 mm, the maximum temperature at the
crack tip was 513°C (955 °F).
Figure 6 shows fractographs of the
base metal and the material of d = 8.8
700 650 600 550 500 450 mm. The maximum temperatures of each
MAXIMUM TEMPERATU RE AT CRACK TIP, fractograph obtained using Fig. 4 are
Imax C O 620°C (1148°F) and 530°C (986°F). In Fig.
Fig. 5 —Relation between the logarithm of grain size and the maximum 6A, the fractograph shows clearly that the
temperature at the crack tip. crack surface was partly melted. In Fig. 6B,

364-s I SEPTEMBER 1990

however, a flat region is mainly observed
with less irregularities.
I-
Z
Study of GMA Welds UJ
2
Longitudinal Crack
oa_!
When GMA welding is performed, fea- UJ
tures of the development of the cracks >
depend on the filler metals employed (Ref.
3). Only transverse cracking is developed I
in the case of 4043 filler metal. In the case O
OC
of 5356 filler metal, however, longitudinal <
cracking, which is along the partially UJ
tn
melted zone near the fusion boundary as UJ

shown in Fig. 7, is also developed besides

tr
the transverse cracking. Two of the au-
thors already have reported this phenom- -In the case of base metal; B —in the case
Fig. 6-Examples of fractographs of fracture surface. A
enon (Ref. 3). A further investigation of of grain size of 8.8 mm. 2
longitudinal cracking was made, paying
a
o
attention to the changes of the solidus
temperature when the heat input was
changed.
i
Influence of Heat Input and Augmented o
Strain oc
<
UJ
Figures 8A and B show the relations be- tn
UJ
tween the crack length L and the heat in- oc
put Q (kj/cm), and between the crack
length and augmented strain e, respec-
tively. The crack began to develop when
the heat input was greater than 2 kj/cm 2
a.
and increased initially linearly with an O
increase in the heat input. The slope of the
crack length vs. the heat input tended to
decrease when the heat input was greater
than 7 kj/cm. No crack was observed for
an augmented strain of 1.0%. When the o
oc
augmented strain became larger than <
1.0%, the crack length tended to increase UJ
tn
with an increase in the augmented strain. UJ
Molten regions were clearly observed cc
on the crack surface near the molten Fig. 7-Macro structure of the cross-section of longitudinal crack.
z
UJ
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LONGITUDINAL CRACK ui
16
LONGITUDINAL CRACK >
16 UJ

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0 2 4 6 8 0.0 1.0 2.0 3.0 4.0 5.0 6.0 tn

10
HEAT INPUT, 0 (kJ/cm) AUGMENTED STRAIN, e (%)
Fig. 8 — Influence of heat input and augmented strain on crack length of longitudinal crack. A — Relation between crack length and heat input; B — Re-
lation between crack length and augmented strain.

WELDING RESEARCH SUPPLEMENT 1365-s

 620

(6061)

20 40 60 100
0 20 40 60 80 100 DILUTION BY BASE METAL, D (%)
DILUTION BY BASE METAL, D ( I ) Fig. 10 — Relation between solidus temperature and dilution (experimen-
Fig. 9 - Relation between solidus temperature and dilution (after Ref. 2). tal value).

pool, but the area of such regions de- When the A6061 alloy was actually GMA minimum value 514°C (957°F) at the dilu-
creased when approaching the crack end. welded using 5356 filler metal, longitudinal tion of 85%, and after that gradually
These effects are consistent with results cracking was observed, but contrary to increased with decreases in the dilution. A
already reported by t w o of the authors Gittos, et ai, it was not observed that the decrease in the dilution corresponds to a
(Ref. 3). solidus temperature of the weld metal decrease in the heat input in the actual
became higher than that of the base metal welding. In the case of 5356 filler metal,
(Ref. 3). the solidus temperature initially decreased
Study on Solidus Temperature
This aspect was investigated further, down to 573°C (1063°F) and after that
Gittos, et ai, obtained the relation using carefully controlled alloy composi- increased up to 580°C (1076°F) at the di-
shown in Fig. 9 between the solidus tem- tions. Specimens were obtained by melt- lution of 65%. With further decreases in
perature Ts and the dilution D by the base ing different ratios of the base metal and the dilution, the solidus temperature de-
metal, using the Al-Mg-Si ternary phase the filler metal using a high-frequency in- creased down to 554°C (1029°F) at the
diagram (Ref. 2). Because of intermediate duction heating furnace. Using these spec- dilution of 15%, and after that tended to
phases formed in this system, in the range imens, the solidus temperature was mea- increase again.
of the dilution between 50 and 90%, the sured for an average cooling rate be- These relations between the solidus
predicted solidus temperature of the weld tween the liquidus and the solidus temperature and the dilution are qualita-
metal was higher than that of the base temperatures of about 30°C/s (54°F/s). tively the same as those shown in Fig. 9.
metal when 5356 filler metal was used. The result thus obtained is shown in Fig. However, the phenomenon that the soli-
They reported that a crack would be de- 10. In the case of 4043 filler metal, the dus temperature in the case of 5356 filler
veloped along the fusion boundary in this solidus temperature abruptly decreased metal is higher for certain dilutions than
region (they performed the Patch test). from that of the base metal (597°C) to the that of the base metal was not observed.
Moreover, the solidus temperature shown
in Fig. 10 is generally lower than that
Fig. 11-Relation 60 shown in Fig. 9. This is considered to be
between dilution ~ due to the phenomenon that small
and heat input. w
amounts of minor solute elements greatly
50
affect the solidus temperature in addition
to the effects of Mg and Si (Ref. 5).
The dilution actually obtained de-
pended on both heat input and filler
metal, as shown in Fig. 11, A similar
tendency is observed in each case, that is,
the dilution initially increases and after that
the slope of the dilution vs. the heat input
tends to decrease with further increases in
the heat input. When the heat input
increased from 1.8 to 9.2 kj/cm, the dilu-
tion increased by about 20%. Generally,
the dilution in the case of 4043 filler metal
4 6 10 is larger by about 10% than in the case of
HEAT INPUT, Q (kj/cm) 5356 filler metal.

366-s | SEPTEMBER 1990

Table 2—Possible Low-Melting Eutectics in
Al-Mg-Si Alloys
u
0
Melting
Eutectics Temperature (° C) S-.

AI-Mg2Si 595
111
Al-Si 579 D2
AI-Mg2Si-Si 559 D

AI-Mg2Si-(FeMn)3Si2Al15-Si <550 <

AI-Mg2Si-FeMg3Si6Als-Si 549 OL
m
Al-Mg2Si-(CrFe)4Si4Ah3-Si <550 a.
AI-CuAI2-Mg2Si 514 UJ
AI-Cu2Mg8Si6Al5-CuAI2-Si 507
to

Figure 12 shows the relation between

the solidus temperature and the heat Fig. 12-Relation
input, obtained by combining Figs. 10 and between solidus
11. The solidus temperature decreased 2 4 6 10 temperature and
HEAT INPUT, O (kJ/cm) heat input.
from 556° to 540°C (1033° to 1004°F) in
the case of 4043 filler metal, but increased
from 560° to 572°C (1040° to 1062°F) in
the case of 5356 filler metal with increases partially melted zone. That is, the weld When augmented strain is constant, the
in the heat input from 1.8 to 9.2 kj/cm (4.6 metal welded using 5356 filler metal has crack length increases with an increase in
to 23 kj/in.). This tendency is qualitatively already solidified, while liquid remains in the heat input as shown in Fig. 8A, be-
the same as that reported earlier (Ref. 3), the HAZ, and longitudinal cracking is de- cause the region which is heated above
but the solidus temperature in Fig. 12 is veloped. In the case of 4043 filler metal, the melting temperature widens. More-
generally lower by 15° to 20°C (27° to however, the weld metal has not yet so- over, the crack length increases for the
36°F). lidified and the cracking is not developed. same heat input with an increase in aug-
Considering the small difference in the mented strain, as shown in Fig. 8B, be-
solidus temperatures between these, and cause the crack can be propagated into
Mechanism of Cracking that longitudinal cracking is developed regions which contain less molten metal.
As already mentioned, longitudinal only in the case of 5356 filler metal, the
cracking is developed along the partially AI-Mg2Si-Si ternary eutectic, which con-
molten zone. This was clearly confirmed tains 4.6% Mg and 13.2% Si and whose Transverse Cracking
melting temperature is 559°C (1038°F) Features of Cracking
to be liquation cracking by the crack
surface observation. This phenomenon (Ref. 7), seems to be the most likely to In the case of 4043 filler metal, trans-
shows that the weld metal has already so- cause the constitutional liquation of all the verse cracking was observed in the HAZ
lidified when the crack is developed. That reactions listed in Table 2. However, ac- even in as-welded condition. In the case of
longitudinal cracking is devleoped only in cording to Mondolfo (Ref. 6), the melting 5356 filler metal, however, the cracking
the case of 5356 filler metal can be well temperature of the AI-Mg2Si-Si ternary was hardly observed as welded, but was
explained by constitutional liquation (Ref. eutectic is 550°C (1022°F), i.e., a differ- observed after machining-off the weld
3). Table 2 shows the compounds and/or ence of 9°C (16° F) from the value shown reinforcement.
eutectics and their melting points, which in the Metals Handbook. Hence, other
Figures 13A and B schematically show
have some probability for development in eutectics having melting temperatures
the features of the cross-section of the
Al-Mg-Si alloys (Refs. 6, 7). around 550°C in Table 2 may contribute
weld bead and the cracks in the cases of
to the constitutional liquation.
Longitudinal cracking was developed at 4043 and 5356 filler metals, respective-
heat inputs larger than 2 kj/cm (Fig. 10A), It is difficult to confirm whether these ly (for t = 4.0%, Q = 6.7 kj/cm). The
and the weld metal solidus temperature at ternary eutectics are actually developed. hatched regions represent the cracked
this heat input is 5 6 0 ° C - F i g . 12. The soli- However, previous work has detected regions. These clearly show that the fea-
dus temperature for the same conditions high amounts of solutes such as 2 ~ 7% tures of the penetration and the crack
in the case of 4043 filler metal is Mg and 5 ~ 9% Si by analyzing the crack largely depend on the filler metals. Gen-
556°C Longitudinal cracking must occur surface using an EDX (Ref. 3). This sup- erally, the width of the weld bead is wider
when the weld metal is essentially solid, ports the likelihood that the AI-Mg2Si-Si in the case of 4043 filler metal, but the
with more continuous liquid paths in the ternary eutectic is the critical reaction. depth of the penetration is almost the

CRACKED CRACKED
REGION REGION

BASE METAL BASE M E T A L

Fig. 13 — Shape of cross-section of weld bead and transverse crack.
A—In the case of 4043 filler metal; B — in the case of 5356 filler metal.

WELDING RESEARCH SUPPLEMENT 1367-s

 4043 FILLER METAL
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HEAT INPUT, Q (kJ/cm)
Fjg. 14 —Relation between the maximum length of transverse crack and Fig. 76 — SEM images and Si K a images at some locations in Fig. 15. A •
heat input. A - For 4043 filler metal; B - for 5356 filler metal At location A; B — at location B; C — at location C

Factors Affecting Cracking and

P A R T I A L L Y MOLTEN HEAT AFFECTED Their Influences
ZONE ZONE

Figures 14A and B show the relation

between the maximum transverse crack
length and the heat input in the cases of
4043 and 5356 filler metals. The critical
3» heat inputs at which the cracking began to
develop were 1.4 kj/cm and 1.8 kj/cm
d*-"^ - 1 ci (3.5 kj/in. and 4.5 kj/in.), respectively. At
B 1 B |
heat inputs larger than the critical value,
Fig. 15 —SEM image the maximum crack length increased with
of crack in the case B lOO^m
increases in the heat input. When the heat
-*"?
of 4043 filler metal. input was constant, the maximum crack
length increased with increases in the
augmented strain. No crack was observed
same. Therefore, the dilution is larger in shallow at this region). The crack in this at the augmented strain less than 1.0% in
the case of 4043 filler metal for the same case was sometimes observed after ma- both cases.
heat input, as shown in Fig. 11. In the case chining-off the specimen surface of the As is clear when comparing Figs. 14A
of 4043 filler metal, most of the crack original base metal a little (less than 0.2 with 14B, the maximum crack length in the
length is observed on the surface of the mm). Most of the cracks were propagated case of 4043 filler metal is about one and
base metal region. In the case of 5356 filler from the fusion boundary into the HAZ, a half times longer than in the case of 5356
metal, however, it is hidden under the though some of the cracks were ob- filler metal for the same augmented strain
weld reinforcement (as is clear from the served a little apart from the fusion bound- and the heat input. This shows that the
figure the depth of the penetration is very ary into the base metal. kind of filler metal greatly affects trans-

368-s I SEPTEMBER 1990

 PARTIALLY MOLTEN I HEAT AFFECTED
-1 ZONE | ZONE
A 4
• « »

i>
* / ' ' "'•
.
*?h #V5 - lb
**' /- ^*»*|**'%
.*%.' *• .-|. ! % • ' * _,**•
vfc'»"«: 1 k

JCst-
l Fig. 18-SEM image
/^ of crack in the case
V*. ,
*-- * \.'#-.;' B^pi of 5356 filler metal.
t u^.

.. . e-W
50/rn

' ' % MM,^ ' .A, .

y**S B ^^,^^v'" •
"^.- - 'jf „ • ..VV-'
ililiiiiiilfi
Sa&MEEeMSiHnfl
N * «?' , so,™ 50
sBfiHl '"" j

Fig. 17 — Another example of SEM image and Si

K a. A —SEM image; B — SiKa image.

verse cracking. This phenomenon is qual-

itatively the same as that reported earlier ^SjyEJiaeJK
(Ref. 3).
i 1)
Figure 15 shows a photograph of the
crack using an SEM in the case of 4043 filler
•> • . 5.......
metal. The crack is along a grain boundary. *, * . »*»•.*» •*-

Fractographs using an SEM clearly showed

that partial melting had occurred. Figures v
v • , • • • . . . ' . . - • • .•••-..

16A-C show SEM images and Si K a

images at locations A, B and C in Fig. 15.
Fig. 19-SEM images
The position A belongs to the partially
melted zone and much Si is observed
here. The position B is nearly halfway
w
P1F' and Mg K a images
at some location in
along the crack and a high Si concentra-
tion is observed near the crack. The posi- -' *-
• .. .' a
/ ** * - J '
-^ *—
.'"*"*-*.' l^^^^M
raP Fig. 18. A-at
location A; B — at
location B; C — at
tion C is the crack end and no marked dis-
tribution of silicon is observed in this case.
SO^m
mm [ 50/"r, |
location C.

Figure 17 shows another SEM image and

Si Ka image at the location of about half-
way along a crack different from that of the heat input on solidus temperature fusion boundary besides the main crack.
shown in Fig. 15. A high concentration of was found for 5356 filler metal (Fig. 12), Figures 19A-C show SEM images and Mg
Si is distributed near the crack. No such but cracking still increased with increased K a images at locations A, B and C in Fig.
distribution of Si was observed near grain heat input —Fig. 14B. This indicates that a 18. The amount of Mg is less at location A,
boundaries where there was no crack. decrease in solidus temperature alone in the partially melted zone. At locations B,
This shows that Si penetrates along grain does not explain the effect of the heat in- nearly halfway along the crack, and C, the
boundaries when welded using 4043 filler put. Instead, this phenomenon is due to crack end, marked distributions of Mg are
metal. As shown in Fig. 14 A, the maximum the fact that the distance corresponding observed near the crack. Figure 20 shows
crack length increased with an increase in to the difference between liquidus and another SEM image and M g K a image
the heat input. A decrease in weld metal the solidus temperatures becomes longer halfway along a crack different from that
solidus temperatures with increased heat with an increase in the heat input. shown in Fig. 18. A high concentration of
input for 4043 filler metal (Fig. 12) may Mg is observed near the crack. Mg is also
Figure 18 shows a photograph of trans-
contribute to increased cracking by pro- considered to penetrate along the grain
verse cracks obtained when using 5356
viding liquid over a longer time (and boundary, similar to the case of Si. How-
filler metal. In this case, many short cracks
distance). However, the opposite effect ever, it is difficult to explain the develop-
were observed at locations apart from the

WELDING RESEARCH SUPPLEMENT I 369-s

 1) The maximum length of liquation
cracking of Alloy 6061 in the case of GTA
spot welding increased greatly with in-
creases in the grain size from 0.05 to 2
mm, but increased slightly for further
increases in the grain size.
2) In the material having the grain size
of about 0.05 mm, liquation cracking was
developed at the region that was heated
above approximately the solidus temper-
ature. When the grain size was coarsened,
however, the crack developed to lower
temperatures than the solidus tempera-
ture.
3) Over a wide range of dilution the
solidus temperature in the case of 5356
Fig. 20 — Another example of SEM image and Mg K a. A— SEM image; B — Mg K a image. and 4043 filler metals, the solidus temper-
ature was increased by Si, but decreased
by Mg. Generally, the solidus temperature
ment of the short cracks shown in Fig 18 ists above the base metal over the region was higher in the case of 5356 filler metal,
by this mechanism only. of the width w. This indicates that Mg in but in both cases the base metal solidus
Most of the cracks were hidden under the weld reinforcement can penetrate temperature was still higher.
this region of weld reinforcement. As downward over the region of the width 4) For GMA welding, longitudinal crack-
sketched in Fig. 13B, in the case of 5356 w. Hence, it is possible to give a consistent ing was developed along the fusion
filler metal, weld reinforcement generally explanation that the short cracks can be boundary only in the case of 5356 filler
occurred over a certain width w of mac- developed as observed in Fig. 18. More- metal. This phenomenon is explained us-
roscopically unmelted base metal. Figure over, it is similarly possible to explain that ing the relation between the solidus tem-
21 shows the relation between the width much Mg is observed near the cracks in peratures and the heat input, plus consti-
w of this region and the heat input. The Fig. 19 and even near the short cracks in tutional liquation in the base metal.
width w was 1.5 mm (0.06 in.) at the heat Fig. 20. 5) Transverse cracking was developed
input equal to 1.8 k|/cm with no observ- Figures 22A and B show an SEM image for both of 4043 and 5356 filler metals.
able cracks, and increased with increases and Si K a image after a Varestraint test The maximum crack length was longer in
in the heat input. In Fig. 2 1 , the relation when GMA welding was performed on
between the maximum crack length and 99.999% Al with 4043 filler metal. A short
the heat input in the case of t = 4.0%, crack is observed along the grain bound-
shown in Fig. 14B, is also shown. The ary, and Si distributes along the crack. This
width w is larger than the maximum crack also confirms that penetration of Si or Mg
length in the case of the small heat inputs, affects transverse cracking.
and they are almost the same in the case
of the heat inputs larger than 8 kj/cm (20
kj/in). Thus, the change of the width w Conclusions
affects the maximum crack length. The
The main conclusions obtained in this
reinforcement-added 5356 filler metal ex-
investigation are as follows:

Fig. 21-Relation
between the width
w and heat input. '

2 1 6 10
HEAT INPUT, Q (kj/cm)

Fig. 22 —SEM image and Si K a image when

CMA welding was performed on 99.999% Al
using 4043 filler metal A — SEM image; B — SiK
a image.

370-s | SEPTEMBER 1990

the case of 4043 filler metal. inforcement above the cracked region welds of Al-Mg-Si alloys using the Varestraint
6) Transverse cracking was observed into the HAZ. test. Welding journal 66(9):251-s to 259-s.
as welded in the case of 4043 filler metal, 4. Kerr, H. W., and Katoh, M. 1987. Investi-
but was hidden under the weld reinforce-
gation of heat-affected zone cracking of GTA
welds of Al-Mg-Si alloys using the Varestraint
Z
Ui
ment and observed after machining off
the reinforcement in the case of 5356 filler
References test. Welding journal (,6^2)360-s to 368-s. S
metal. 1. Tsujimoto,k. Sakaguchi,A.,Kinoshita,T.,
5. Gustafsson, G., Thorvaldsson, T., and a
Tanaka, K., and Sasabe. S. 1983. HAZ cracking
Dunlop, G. L. 1986. The influence of Fe and Cr O
7) In the case of 5356 filler metal, on the microstructure of cast Al-Si-Mg alloys. _i
of Al-Mg-Si alloys. IIW Doc. IX-1273, pp. 1-13. ui
besides long transverse cracks, many short
2. Gittos, N. F„ and Scott, M. H. 1981. Heat-
Met. Trans. 17A(1):45-52. >
cracks were observed a little apart from 6. Mondolfo, N. F. 1979. Aluminum alloys: UJ
affected zone cracking of Al-Mg-Si alloys.
the partially melted zone. The develop- Welding journal 60(6):95-s to 103-s.
structure and properties. Butterworths: p. 795. a
ment of these cracks is considered to be 3. Katoh, M., and Kerr, H. W. 1987. Investi-
7. Metals Handbook Vol. 8. 1973. ASM
International, Materials Park, Ohio, p.396.
x
o
caused by Mg diffusing from the weld re- gation of heat-affected zone cracking of GMA oc
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WRC Bulletin 343 Z
Ul
May 1989 2
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Destructive Examination of PVRC Weld Specimens 2 0 2 , 2 0 3 and 251J ui
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This Bulletin contains three reports: x
a
oc
( 1 ) Destructive Examination of PVRC Specimen 202 Weld Flaws by JPVRC <
UJ
By Y. Saiga tn
Ul
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( 2 ) Destructive Examination of PVRC Nozzle Weld Specimen 203 Weld Flaws by JPVRC
ui
By Y. Saiga S
a
O
( 3 ) Destructive Examination of PVRC Specimen 251J Weld Flaws _i
ui
By S. Yukawa >
Ul
The sectioning and examination of Specimens 202 and 203 were sponsored by the Nondestructive
Examination C o m m i t t e e of the Japan Pressure Vessel Research Council. The destructive examination of
a
Specimen 251J was performed at the General Electric Company in Schenectady, N.Y., under the
x
o
sponsorship of the S u b c o m m i t t e e on Nondestructive Examination of Pressure Components of the CE
<
Pressure Vessel Research C o m m i t t e e of t h e Welding Research Council. The price of WRC Bulletin 343 is Ul
(A
$24.00 per copy, plus $5.00 for U.S., or $8.00 for overseas, postage and handling. Orders should be sent Ul
with payment to the Welding Research Council, Room 1 3 0 1 , 345 E. 47th St., New York, NY 10017. Ct
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Invitation to Participate in the Inaugural Ul
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Meeting of the AWS G2 Committee o
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on Joining Metals & Alloys Ul
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This c o m m i t t e e was approved at the Spring meeting of the AWS Technical Council. The Scope of the -**.
c o m m i t t e e is as follows: i-
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To survey industry groups and identify need for information on joining spe- S
a.
cific families of alloys. Identify and select specific groups or classes of alloys O
t h a t are sufficiently alike so t h a t a single standard can be logically prepared -j
UJ
on the joining of these metals. >
Ul
Recruit additional c o m m i t t e e and s u b c o m m i t t e e members to prepare the a
selected standards.
2
The first meeting of the G2 C o m m i t t e e will be held on November 5 and 6, 1990 in Newport News, Va. <
Anyone interested in attending the meeting should contact Leonard P. Connor of the American Welding m
Society (800) 4 4 3 - 9 3 5 3 . tn
UJ
tr

W E L D I N G RESEARCH SUPPLEMENT 1371-s

 WRC Bulletin 352
April 1990
In October 1987, the PVRC Steering and Technical Committees on Piping Systems established a task
group on independent support motion (ISM) to evaluate the technical merits of using the ISM method of
spectral analysis in the design and analysis of nuclear power plant piping systems.
The results of the task group evaluation culminated in a unanimous technical position that the ISM
method of spectral seismic analysis provides more accurate and generally less conservative response
predictions than the commonly accepted envelope response spectra (ERS) method, and are reported in
this WRC Bulletin. The price of WRC Bulletin 352 is $25.00 per copy, plus $5.00 for U.S., or $10.00 for
overseas, postage and handling. Orders should be sent with payment to the Welding Research Council,
345 E. 47th St., Room 1301, New York, NY 10017.

WRC Bulletin 353

May 1990
Position Paper on Nuclear Plant Pipe Supports

This position paper recommends design methods which represent the collective "best methods" of the
industry. These enhanced design methods are developed by reviewing the issues that have added to the
complexity of design and fabrication of piping systems.
Publication of this report was sponsored by the Task Group on Nuclear Plant Pipe Supports of the
Technical Committee on Piping Systems of the Pressure Vessel Research Council of the Welding Research
Council. The price of WRC Bulletin 353 is $25.00 per copy, plus $5.00 for U.S., or $10.00 for overseas,
postage and handling. Orders should be sent with payment to the Welding Research Council, 345 E. 47th
St., Room 1301, New York, NY 10017.

WRC Bulletin 354

June 1990
The two papers contained in this bulletin provide definitive information concerning the elevated tem-
perature rupture behavior of 2V4Cr-lMo weld metals.

( 1 ) Failure Analysis of a Service-Exposed Hot Reheat Steam Line in a Utility Steam

Plant
By C. D. Lundin, K. K. Khan, D. Yang, S. Hilton and W. Zielke

( 2 ) The Influence of Flux Composition of the Elevated Temperature Properties of Cr-Mo

Submerged Arc Weldments
By J. F. Henry, F. V. Ellis and C. D. Lundin

The first paper gives a detailed metallurgical failure analysis of cracking in a longitudinally welded hot
reheat pipe with 184,000 hours of operation at 1050°F. The second paper defines the role of the welding
flux in submerged arc welding of 2V4Cr-lMo steel.
Publication of this report was sponsored by the Steering and Technical Committees on Piping Systems
of the Pressure Vessel Research Council of the Welding Research Council. The price of WRC Bulletin 354
is $50.00 per copy, plus $5.00 for U.S. and $10.00 for overseas postage and handling. Orders should be
sent with payment to the Welding Research Council, 345 E. 47th St., Room 1301, New York, NY 10017.

372-s | SEPTEMBER 1990