Study on the solidification cracking behaviour of high strength aluminum alloy welds: Effects of alloying elements and solidification behaviours

The solidification cracking susceptibility of the 7000 series Al-Zn-Mg high strength aluminum alloy has been studied. The cracking behaviour of the specimens were evaluated by a Tig-a-Ma-Jig Varestraint test process under various augmented strain conditions. It has been experimentally observed that the addition of copper decreased the solidification cracking resistivity of the high strength aluminum alloy weld metal by increasing the total crack length (TCL). The effect of the addition of manganese on the solidification cracking behaviour is found to be beneficial by markedly decreasing the solidification cracking susceptibility as the manganese content increases from 0.3 to 0.7%. This enhancement by manganese is understood to be attributed to the reduction of the mushy zone size during the solidification process. The effects of chromium and zirconium additions are also investigated. The weld metal containing zirconium is less sensitive to the solidification cracking than the weld metal containing chromium. In addition, the solidification behaviours of the tested alloys are also investigated and it is found that as the solidification temperature range (T) becomes narrow, the solidified structure becomes more dendritic in its features which is believed to create higher solidification cracking resistance.