Analysis of crack in aluminium alloy AA2219 weldment

Aluminium alloy AA2219 is used for fabrication of propellant tanks of launch vehicles. After welding of one of the heat treated plate (T87 temper condition) with a rolled ring (T851 temper condition), crack has been noticed near the weldment. A thorough metallographic analysis was carried out to investigate the cause for development of crack, using optical and scanning electron microscope. Morphology of cracks alongwith the attributable factors are discussed and the remedial measures are suggested.     

Effect of cathodic potential on stress corrosion cracking behavior of different heat-affected zone microstructures of E690 steel in artificial seawater

In this work,the stress corrosion cracking(SCC)behavior of E690 steel base metal(BM)and different heat-affected zone(HAZ)microstructures,i.e.,coarse grain HAZ(CGHAZ),fine grain HAZ(FGHAZ),and intercritical HAZ(ICHAZ),was investigated at different cathodic potentials in artificial seawater by slow strain rate tensile tests,scanning electron microscopy and electron back-scattered diffraction measurements.The results show that the HAZ microstructures and BM exhibit different SCC susceptibilities:FGHAZ相似文献   

Interplay of microbiological corrosion and alloy microstructure in stress corrosion cracking of weldments of advanced stainless steels

This paper presents an overview of the phenomenon of stress corrosion cracking (SCC) of duplex stainless steels and their weldments in marine environments and the potential role of microbial activity in inducing SCC susceptibility. As a precursor to the topic the paper also reviews the performance of the traditional corrosion-resistant alloys and their weldments and the necessity of using duplex stainless steels (DSS), in order to alleviate corrosion problems in marine environments. Given that the performance of weldments of such steels is often unsatisfactory, this review also assesses the research needs in this area. In this context the paper also discusses the recent reports on the role of microorganisms in inducing hydrogen embrittlements and corrosion fatigue.     

Effect of pre-strain and two-step aging on microstructure and stress corrosion cracking of 7050 alloy

A novel heat treatment procedure that combines the pre-strain with a two-step aging was proposed to improve both the strength and stress corrosion cracking (SCC) resistance of the high strength 7050 aluminum alloy. The heat treatment included a post-quenching pre-strain of 5%, a high-temperature aging at 200 °C for several minutes, and a subsequent low-temperature aging at 120 °C for 24 h. The yield strength of the samples aged at 200 °C for 0.5 and 1 min was higher than that of the T6 sample. The SCC resistance of these samples was improved compared to the T6 sample, due to the enlargement in the size and the inter-particle distance of the grain boundaries precipitates and the decreases in the number of the GP zone. Especially, the sample aged at 200 °C for 5 min exhibited a similar SCC resistance and much higher elongation compared the T76 sample.     

Influence of constitutional liquation on corrosion behaviour of aluminium alloy 2017A

The purpose of this work was to investigate microstructural aspects of constitutional liquation in the aluminium alloy 2017A and to determine its effect on corrosion behaviour of this alloy. Non-equilibrium melting of the alloy in the naturally aged condition was provoked by rapid heating above the eutectic temperature and immediate cooling in air. Corrosion testing was performed by exposure to a marine onshore atmosphere. The microstructure examinations were carried out using light microscopy, scanning electron microscopy, X-ray energy dispersion and X-ray diffraction analysis. It was found that, due to rapid heating rate, coarse θ (Al₂Cu) particles were melted by constitutional liquation and this way introduced strong susceptibility of 2017A alloy to intergranular corrosion.     

Study of microstructural and mechanical properties of weld heat affected zones of 2024-T3 aluminium using Gleeble simulation

Abstract

The effect of the microstructural properties on the mechanical properties of welding thermal cycles and post-weld heat treatment of the heat affected zone (HAZ) in 2024-T3 aluminium alloy has been investigated. Gleeble HAZ simulation, differential scanning calorimetry, TEM and tensile test have been utilised to investigate the regions representative of HAZ microstructures. The decay of strength in the weld HAZ is primarily due to the precipitation and coarsening of stable S phases. The welded HAZ in the region at peak temperature of 414°C has the lowest strength after natural aged temper. Post-weld T81 artificial aging (PWAA-T81) heat treatment at 190°C for 12 h has no effect on improving the HAZ strength; the HAZ strength of 2024-T3 alloy obtained by PWAA-T81 treatment is less than that obtained by natural aging, and its lowest strength is shifted to the region of the peak temperature, which is 452°C. Scanning electron microscopy observation reveals that the fracture mode changes from transgranular to intergranular failure when the 2024 specimen is exposed to a thermal cycle up to a peak temperature of 550°C. This is caused by the liquation of grain boundary segregates or formation of a eutectic structure while the specimen is subjected to high temperature thermal cycles during welding, which results in a decrease in the strength and ductility of the grain boundary. It is also shown that the decrease in ductility in this high temperature HAZ cannot be improved using the PWAA-T81 heat treatment.     

Numerical simulation of solidification and liquation behavior during welding of low-expansion superalloys

Low-expansion superalloys are susceptible to weld solidification cracks and heat-affected zone (HAZ) microfissures. To predict solidification cracking, QBasic procedures were developed and solidification reaction sequence, type, and amount of eutectic product were calculated. As manifested, primary solidification is followed by L → (γ+NbC) and L → (γ+Laves) eutectic reaction sequentially for GH903 and GH907; hence, the terminal eutectic constituents are made up of γ/NbC and γ/Laves. While for GH909, only reaction L → (γ+Laves) occurs and more γ/Laves eutectic forms. Therefore, GH909 is more sensitive to solidification cracking. To predict HAZ liquation, cracking Visual FORTRAN procedures were developed, and constitutional liquation of NbC was simulated. As shown, solid dissolution of NbC prior to liquation decreases, and initial liquid film increases with the rate of thermal cycle. Higher rate of thermal cycle promotes the melting of the matrix adjacent to the liquid film and postpones the solidification of the liquid by the liquid-to-γ mode. Thus, more residual liquid film remains at the eutectic point, which will promote HAZ microfissuring. The increase in original grain size and peak temperature also promotes liquation. Finally, these conclusions were verified indirectly by hot ductility tests.     

Environmentally assisted cracking of aluminium alloys

A short review of the stress corrosion cracking (SCC) behaviour of aluminium alloys is given. Mechanisms of environmentally assisted cracking are outlined. For aluminium alloys, in which stress corrosion cracks propagate predominantly along grain boundaries, anodic dissolution and hydrogen embrittlement have been proposed. Transgranular stress corrosion cracking occurring at severe loading conditions has found particular interest concerning localised corrosion‐deformation interactions. Accelerated test methods for assessing the SCC behaviour are described, including the slow strain rate testing technique and the breaking load method. Results of recent studies on environmentally assisted cracking of aluminium alloys are summarised. Most of the work published in the last two decades has been on aluminium‐lithium based alloys and improved high strength Al‐Zn‐Mg‐Cu alloys in corrosion resistant retrogressed and re‐aged tempers.     

Modification of residual stress and microstructure in aluminium alloy by cryogenic treatment

The effect of cryogenic treatment (CT) combined with solution and ageing treatment on the residual stress and microstructure of 7050 aluminium alloy was investigated. The relationship between residual stress and microstructure was discussed. The results showed that compared to solution–ageing treatment (SA), CT after solution and before ageing (SCA) exhibited lower level and higher uniformity of residual stress. The highest dimensional stability was also obtained by the process of SCA. It was found that CT induced the fine precipitates through the lattice contraction under cryogenic temperature. Furthermore, the execution of CT in advance would also promote the uniform distribution of precipitates in the subsequent ageing by releasing and homogenising the residual stress.     

Enhancing stress corrosion cracking resistance in Al-Zn-Mg-Cu-Zr alloy through inhibiting recrystallization

The aim of the work was to inhibit recrystallization in Al-Zn-Mg-Cu-Zr alloy and to evaluate the stress corrosion cracking (SCC) behavior of the alloy in the peak aged condition. For this purpose, scandium addition was made to an Al-Zn-Mg-Cu-Zr alloy as the former inhibits recrystallization. The scandium-containing alloy was heat-treated to peak aged condition and compared with the base peak aged alloy which contained recrystallized grains. The SCC susceptibilities of the alloys were evaluated using slow strain rate testing (SSRT) and U-bend techniques. While, the base alloy having recrystallized grains showed drastic loss in ductility in the corrosive environment (3.5 wt.% NaCl solution), the scandium-containing alloy having un-recrystallized and fine grains showed no significant loss in ductility in the similar environment. The fracture surface analysis revealed typical intergranular cracking of recrystallized grains in the base alloy, whereas in the scandium-containing alloy predominant ductile failure was observed. Thus, the study clearly indicated that inhibiting recrystallization in Al-Zn-Mg-Cu-Zr alloy through scandium addition, the SCC resistance of the alloy can be substantially improved even in the peak aged condition.     

随焊激冷防止高强铝合金焊接热裂纹的数值模拟

采用热弹塑性有限元方法对随焊激冷防止焊接热裂纹的工艺过程进行了数值模拟 ,动态定量地描述了温度场、位移场和应变场的演变过程 ,清晰地揭示了随焊激冷防止焊接热裂纹的机理及主要参数的影响规律 .研究表明 ,随焊激冷能够通过冷源作用区的冷却收缩造成对其前方处于BTR金属的横向挤压 ,推迟塑性拉伸应变的开始形成温度并减缓其发展速率 ,因而降低热裂纹倾向 ;采用较小的激冷距离有利于降低热裂纹倾向 ,在激冷距离较大时提高激冷功率仍有防止热裂纹的作用 ;加大外部拘束会在一定程度上削弱随焊激冷防止热裂纹的效果 .     

The relationship between fatigue crack behaviour and microstructure in 7178 aluminium alloy

Relationships between fatigue crack growth rates and crack path have been studied in under aged, peak aged and over aged 7178 aluminium alloy microstructures. The superior resistance to crack growth of over aged material is derived from the greater crack tip irregularity that the microstructure imposes. Conversely, the poor crack growth resistance of material aged to peak hardness is associated with relatively flat fracture surfaces. Changes in crack tip regularity while the crack is extending control the slope of the crack growth rate curve.     

Influence of deformation process on microstructure and properties of 2014 aluminium alloy

The comparisons of forging-extrusion multistage hot deformation, forging and extrusion hot deformation processes on microstructure, mechanical property and impact toughness of 2014 Al alloy have been investigated. Results showed that the strength and impact toughness of the samples under forging-low extrusion multistage deformation process were significantly improved compared with that under forging deformation process due to the formation of smaller insoluble particles, finer grains and higher density of matrix precipitates. However, the strength and impact toughness of the samples under forging-extrusion multistage hot deformation process are lower than that under extrusion hot deformation process. The strengthening and fracture mechanisms with different deformation process have been discussed in detailed.     

Control of microstructure and earing behaviour in aluminium alloy AA 3004 hot bands

Abstract

Control of earing behaviour at the hot band stage is a critical requirement for successful manufacture of aluminium alloy sheet for beverage cans. The present study has combined production scale experiments with laboratory examinations to investigate the effect of various material and process parameters on microstructure, texture, and earing of the resulting products. It is shown that optimisation of the product is strongly dependent on (i) iron content of the alloy, (ii) ingot homogenisation temperature, (iii) finish hot rolling temperature, and (iv) heating rate during hot band annealing. Earing level after annealing is shown to depend on the balance between cube (+ Goss) texture intensity and the volume of material having almost randomly spread orientations. Pronounced 0/90° earing tendency is usually associated with coarse and elongated grain structures. A model is shown which represents the microstructure–texture evolution as a competition between cube/Goss grains, which nucleate systematically within transition bands, and randomly oriented grains, which nucleate in the vicinity of coarse second phase particles.

MST/1032     

Thermal stresses in aluminium alloy die casting dies

The aim of this research is to analyze the influence of Aluminium Alloy die casting parameters, die material, and die geometry on in-service tool life. An innovative immersion testing apparatus is developed, at which Aluminium Alloy die casting is simulated. It enables controlled thermal fatigue cycling. Special specimens with different edge geometry and specimens with maraging steel welds deposited by Gas Tungsten Arc (GTA) welding are prepared. They are subjected to cyclic heating in bath of molten Aluminium Alloy 226 and cooling in bath of water-based lubricant. The specimens are continuously internally cooled with cold water. The microstructure, hardness profile, and the surface cracks developed are periodically analyzed after completion of a particular number of cycles. Temperature transients at different locations of the specimens are measured and used in calibration of finite element model (FEM). The computation of transient stresses is performed by developed FEM. The influence of immersion test parameters, material, specimen edge geometry, and thickness of maraging steel surfacing welds on thermal stresses is studied. To improve thermal fatigue testing efficiency, a specimen of particular geometry and immersion test parameters are developed based on finite element analysis. The results showed significant differences in produced thermal stresses for analyzed materials, test parameters, and edge geometries. Maraging steel is found to be superior material for die casting dies, due to generation of lower stresses.     

Sliding wear behaviour and microstructure of PEO coatings formed on aluminium alloy

In this work, plasma electrolytic oxidation coating was formed on aluminium alloy in a cheap and inexpensive electrolyte to improve its wear resistance. It was found the micro-hardness of coatings increased first and then decreased with increasing the oxidised time. It was showed that the specimen treated under the time of 35 minutes exhibited the highest micro-hardness and lowest wear loss. The surface and cross-sectional morphology indicated that the coatings have a dense structure with low porosity. The presence of wear scars on the worn surface morphology demonstrates that the three-body rolling was the main wear mechanism for coated specimen. X-ray diffraction results showed the coating was formed mainly from α-Al₂O₃ and γ-Al₂O₃.     

Local melting mechanism and its effects on mechanical properties of friction spot welded joint for Al-Zn-Mg-Cu alloy

Local melting and the eutectic film and liquation crack formation mechanisms during friction spot welding (FSpW) of Al-Zn-Mg-Cu alloy were studied by both experiment and finite element simulation. Their effects on mechanical properties of the joint were examined. When the welding heat input was high, the peak temperature in the stir zone was higher than the incipient melting temperature of the Al-Zn-Mg-Cu alloy. This resulted in local melting along the grain boundaries in this zone. In the retreating stage of the welding process, the formed liquid phase was driven by the flowing plastic material and redistributed as a “U-shaped” line in the stir zone. In the following cooling stage, this liquid phase transformed into eutectic films and liquation cracks. As a result, a new characteristic of “U” line that consisted of eutectic films and liquation cracks is formed in the FSpW join. This “U” line was located in the high stress region when the FSpW joint was loaded, thus it was adverse to the mechanical properties of the FSpW joint. During tensile shear tests, the “U” line became a preferred crack propagation path, resulting in the occurrence of brittle fracture.     

Experimental investigation of the hot cracking mechanism in welds on the microscopic scale

The results of the accurate experimental observations on binary Al-Si alloys are presented, which clearly demonstrate that the solidification cracking is a result of the accumulation of macroscopic tensile displacement in aβmicroscopic intergranular liquid film of segregates at the final stage of the weld metal solidification. The reconstructed mechanism of crack initiation provides a clear phenomenological interrelation between the cracking susceptibility, parameters of the welding process and properties of the base and filler material. The correspondent numerical model takes into account the effects of displacement accumulation as well as the influence of thermo-dynamical and thermo-mechanical properties of the welded material. It is successfully applied for development of technological means for elimination of the solidification cracking during welding of aluminium alloys AA6056, such as a multi-beam welding.     

High strain rate deformation and cracking of AA 2219 aluminium alloy welded propellant tank

Aluminium alloy AA 2219 (Al–6.6Cu–1Mn) is the candidate material for the fabrication of propellant storage tank of launch vehicle. Cold rolled sheets of 6.5 mm thickness are used to make the cylindrical shell, while sheets of 4.5 mm thickness are used for the construction of dome through petal forming technique. Petals, formed through cone rolling, treated to T87 temper condition are welded together by TIG welding to configure the dome. Such domes are joined to the cylindrical shell through a ring by TIG welding.The upper stage consists of two tanks, one oxidizer tank (liq. O₂) and other fuel tank (liq. H₂). After completing various developmental qualification tests, propellant flow rate test of one of the system was carried out. Almost all the liquid oxygen of the tank was removed and only a little quantity remained at the bottom. During one of the subsequent tests; when dry nitrogen gas was purged to evaporate the remaining liquid oxygen, the oxidizer tank dome catastrophically fractured with an audible sound. Fracture of oxidizer tank dome, placed at lower part of the system caused excessive deformation and subsequently it also caused fracture of fuel tank dome placed just over it.Detailed metallurgical investigations were carried out on the failed components and it was found that the tank failed under very high strain rate deformation. This paper brings out the details of the investigation carried out.