Control of weld composition when arc welding high strength aluminium alloys using multiple filler wires

Abstract

An experimental method of controlling weld composition when welding Al2024 has been explored. Utilising the tandem process and a cold wire feed unit, two and three commercially available filler wires were mixed in a single weld pool to control composition. Thermodynamic modelling was used to provide optimum weld compositions for the eradication of solidification cracking. Validation showed that by controlling the principal elements, not only was cracking eliminated, the mechanical properties of the weld could be varied. In particular, a composition was identified, which offered adequate joint strength and ductility. Exceeding this composition resulted in a corresponding increase in weld hardness at the expense of joint ductility.