How to Avoid Cracking

When Welding
Aluminum Alloys
By:

Tony Anderson CEng, FWeldI

Director of Aluminum Technology
ITW Welding North America

Welding Discontinuities in Aluminum

Weld Cracking

Porosity

Incomplete Fusion

Causes
&
Correction

Incomplete Penetration

(Hobart Aluminum Brochure - Page 21-33 Problem Solving)

Welding Discontinuities in Aluminum

Characteristics of aluminum that can influence
weld quality
Incomplete Penetration and Fusion

Aluminum has a thermal conductivity 5 times that of

steel & an adherent oxide layer that has a melting
temp. around 3 times that of the aluminum alloy

Welding Discontinuities in Aluminum

Characteristics of aluminum that can influence
weld quality
Porosity
When aluminum is taken
to temp. above its melting
point (as it is when arc
welding) it becomes very
susceptible to hydrogen
absorption - which can
cause porosity
(Hobart Brochure - Page 23-25)

Weld Cracking in Aluminum

Unlike steel aluminum is not susceptible to
Hydrogen Cracking

Hot Cracking - which is sometimes referred to as

solidification cracking or liquation cracking is
the primary reason aluminum welds crack

Hot Cracking - is a high-temperature cracking

mechanism and is mainly a function of how
metal alloy systems solidify

(Hobart Aluminum Brochure - Page 26-28)

Weld Cracking in Aluminum

Understanding - Hot Cracking

Hot cracking is a welding problem that does not occur in

pure metals

The addition of alloying elements to a pure metal can

result in a number of different phases being formed during
solidification

One particular phase is the lowest melting point

composition of an alloy known as the eutectic composition
which freezes at one specific temperature, it is this
eutectic phase that can promote hot cracking

In most metals this effect is caused by impurities, sulphur

in steel and nickel is a good example where low melting
point sulphide eutectics are formed

In aluminum it is the deliberately added alloying elements

that form a range of eutectics with freezing points
substantially lower than the bulk metal

Problem Solving

Weld Cracking in Aluminum

Hot Cracking

If the difference in the melting point between the low melting

point eutectic and the bulk of the metal is sufficiently great then
the liquid film along the grain boundaries may part as the metal
cools and contracts the result of this is hot cracking

Solidification strains are proportional to the temperature interval

over which solidification occurs (Coherence Range)

Weld Cracking in Aluminum

Hot Cracking

In general all aluminum alloys exhibit a peak in hot cracking sensitivity

and a high resistance to hot cracking at both low and high alloy content

On the low alloy content side there is only a small amount of eutectic
present which results in the liquid film on the grain boundaries being
discontinuous or very thin Low crack sensitivity - 1

As the liquid film thickness increases the force required to tear the film
reduces and crack sensitivity increases High crack sensitivity - 2

Once there is sufficient eutectic available it can begin to flow into and fill
any cracks that form Low crack sensitivity - 3
2

Weld Cracking in Aluminum

Hot Cracking
All aluminum alloys are susceptible
to some degree of hot cracking,
differing only in their degree of
susceptibility
Cracking tests have been used to
determine the range of composition
within which an alloy has a high risk
of hot cracking

Problem Solving

Weld Cracking in Aluminum

The chemical composition of the weld which

is most often a mixture of base metal and
filler metal can greatly influence crack
sensitivity

Its all about the chemistry

Weld Cracking in Aluminum

Crack Sensitivity Chart

Crack Sensitivity

0
Al - Cu
0
Al - Mg
0
Al - Mg2 Si
0
1

Percentage alloying element in the weld

(Hobart Aluminum Brochure - Page 26)

Weld Cracking in Aluminum

Crack in 6061-T6 GTAW weld with no filler metal

Radiograph of cracked weld

Weld Cracking in Aluminum

Hot Cracking
Weld on the left
was welded
with the
addition of 4043
filler metal and
we see no
visible cracks

Weld on the
right is welded
without filler
metal
(autogenous)
and we see a
large centerline
crack

Visual Inspection of two welds made with the GTAW process on base metal 6061-T6

Its all about the chemistry

Weld Cracking in Aluminum

Crack Sensitivity Chart

Crack Sensitivity

0
Al - Cu
0
Al - Mg
0
Al - Mg2 Si
0
1

Percentage alloying element in the weld

Area of interest Al-Mg2Si

Weld Cracking in Aluminum

Crack Sensitivity Chart
Crack Sensitivity

6061 Base Metal has Mg2Si Content Around Maximum Crack Sensitivity

Al - Mg2 Si
0
1

Percentage Alloying Element In The Weld

Note: This is the reason that there are no 6xxx series

filler metals they would crack when used

Weld Cracking in Aluminum

Weld A which was welded without filler metal has cracked during solidification
(Hot Crack) owing to the high crack sensitivity of the molten material (6061-T6)

Weld B on the same base material welded with 4043 filler metal has no cracking

WHY?
The 4043 filler metal provides a number of characteristics that help to prevent cracking
when welding the 6xxx series alloys:
It combines with the base metal which lowers the percentage of Mg2Si in the
solidifying weld and thereby reduces crack sensitivity
It has a lower solidification temperature which allows the base metal to solidify
prior to the weld
The addition of higher percentages of silicon to the solidifying weld metal
decreases the total shrinkage during freezing

Weld Cracking in Aluminum

Dilution Effect on Crack Sensitivity
6061 Base Alloy 1% Mg
5356 Filler Alloy 5% Mg
Question: Which
of these two
welds will have
the highest
probability of
hot cracking?
Square-groove weld

Single-v-groove weld

20% Filler Metal

60% Filler Metal
80% Base Metal (Hobart Aluminum Brochure - Page 27) 40% Base Metal

Weld Cracking in Aluminum

Crack Sensitivity Chart

Crack Sensitivity

0
Al - Cu
0
Al - Mg
0
Al - Mg2 Si
0
1

Percentage alloying element in the weld

Area of interest Al-Mg

Weld Cracking in Aluminum

Alloy Content Vs. Crack Sensitivity

Crack Sensitivity

1.8% Mg

3.4% Mg

Al - Mg
0
Composition Of Weld - Percent Alloying Element

Note: When welding the 6xxx series base metals, using a

single-v-groove weld rather than a square-groove weld can
significantly reduce the probability of cracking

Weld Cracking in Aluminum

Typical Dilution Ratios of Welded Joints
20%
Filler
Metal
80%
Base
Metal

60%
Filler
Metal
40%
Base
Metal

80% Filler Metal

20% Base Metal

Weld Cracking in Aluminum

Stress Crack Inside Pipe On The Opposite Side From Weld

Crack
6061-T6
Base Metal

Fillet Weld

Note: Excessive heat and shrinkage stress

Weld Cracking in Aluminum

Solidification Shrinkage Stress Crack

2014 Base metal

melting range
945-1180 Deg. F

4043 Filler metal

melting range
1065-1170 Deg. F

Note: Filler metal 4145 has a melting range of 970-1085 and

would provide the lowest crack sensitivity

Crater Cracking & Weld Termination

Crater Crack
AWS D1.2 2008 Structural Welding Code (4.17) Terminating a weld within a
joint may be done by any of the following methods or combination thereof:
Reversing the direction of travel for a distance of at least 2 in [50 mm]
Increasing travel speed
Providing a build-up of metal and remolding the crater area flush with the weld
surface by mechanical means
Using automated crater fill features in the welding equipment
Rapidly triggering the gun manually as the weld is terminated

Weld Cracking in Aluminum

Plate Edge Cracking
When using thermal cutting
processes on the heat treatable
alloys such as the 6xxx series
there is a potential for cracking to
occur along the plate edge
AWS D1.2 4.11.2 - Plasma arc
and laser cut edges For heat
treatable aluminum alloys, 1/8 in
(3mm) of material shall be
removed by machining from
plasma and laser cut edges that
will be welded

Aluminum Alloys For Marine Service

5xxx Series Alloys

Crack Sensitivity is not usually an issue (hot cracking)

Mg alloys with less than 2.5%Mg (5052) can be welded with

a 4xxx or 5xxx series filler alloy
Mg alloys with more than 3%Mg are usually welded with
filler alloy of very similar chemistry to that of the base alloy
Alloys above 4% Mg can be weld autogenously
No special precautions to be taken when plasma arc cutting
* However the manufacturing & testing procedures of the
5xxx alloys is important when it is used in marine
applications

Aluminum Alloys For Marine Service

5xxx Series Alloys Corrosion Considerations
US Coast Guard (09/25/2003) Aluminum Fracturing
Exfoliation corrosion and fracturing problems have
recently been observed on several high-speed
passenger vessels built in the Puget Sound area
Between 1999 and 2001 there was around 750,000
pounds of 5083 H321 used in the marine industry that
had been produced by a manufacturer using a nonmarine process that made the material susceptible to
intergranular corrosion.
(As a result of this problem we now have ASTM B 928)

Aluminum Alloys For Marine Service

ASTM B 928
ASTM Standard Specification for High Magnesium
Aluminum-Alloy Sheet and Plate for Marine Service
and Similar Environments Designation: B 928/B
928M 07
This specification has been developed to provide assurance to the
manufacturer and the end user that the material used for
manufacturing aluminum vessels has been correctly manufactured
and tested to ensue its suitability for marine applications
Note: what are the materials addressed and how does ASTM B 928 achieve its
objectives?

Aluminum Alloys For Marine Service

Chemical Composition Limits ASTM - B 928

Note: The Specification addresses these alloys in both the H116 & H321 tempers

Aluminum Alloys For Marine Service

5xxx Series Alloys Corrosion Considerations

Sensitization the development of a continuous grain

precipitate in 5xxx alloy temper material, that causes the
material to be susceptible to intergranular forms of
corrosion

Intergranular Corrosion corrosion that preferentially

occurs at, or adjacent to, the grain boundaries of a metal or
alloy.
Exfoliation Corrosion corrosion that proceeds laterally
from the sites of initiation along planes parallel to the
original rolling surface, generally at grain boundaries.

Aluminum Alloys For Marine Service

ASTM B 928
Examples of the corrosion morphology produced by test method G 67, for varying degrees
of sensitization, from pitting and general corrosion to intergranular corrosion.
Fig a and b
Show examples
of general
corrosion and
pitting corrosion
attack. These
samples are
examples that
would pass
Specification
ASTM B 928

Fig c and d
Show examples
of an
Intergranular
attack and are
examples of
material that
would fail
specification
ASTM B 928

Weld Cracking in Aluminum

The Prevention of Hot Cracking
Avoid welding crack sensitive base alloys without filler
metal
Use joint designs that help to ensure adequate additions of
filler metal
Avoid weld profiles that are excessively concaved
Avoid welds that are undersized
Avoid excessive heat input
Reduce excessive localized stresses
Lower solidification temp. filler - relative to base metal
Smaller solidification temp. range
Filler metal selection use the most appropriate filler metal
(use a filler metal selection chart)

Non-Weldable Aluminum Base Metals

WARNING

2xxx alloys with - Aluminum-copper-magnesium

Examples: 2017 and 2024
7xxx alloys with - Aluminum-zinc-copper-magnesium
Examples 7075, 7178, 7050, 7150
Note: Low melting point elements are preferentially precipitated into
grain boundaries lowers and widens solidification temp. range at the
grain boundary. Easily crack during solidification shrinkage, difference
in galvanic potential at grain boundaries can make them susceptible to
stress corrosion cracking

Alloys used for machinability Examples 6262 and 2011

Note: These alloy have lead, bismuth, and/or tin added to facilitate
machinability these low melting additives seriously increase hot
cracking
(Hobart Aluminum Brochure - Page 10)

Aluminum Filler Metal Selection Chart

The Weld Meal Properties Used To Select The Most Appropriate Filler Metal
Crack Sensitivity
Elevated Temperature Service
Strength
Color Match After Anodizing
Ductility
Post Weld Heat Treatment
Corrosion Resistance
Toughness
(Hobart Aluminum Brochure 3 Page fold-out at back of brochure)

Aluminum Alloys For Marine Service

Conclusion
Be aware of the potential solidification cracking issues
associated with welding the 6xxx series aluminum alloys
When procuring 5xxx series aluminum alloys for marine
applications ensure that they are ordered to the correct
temper and that they are manufactured and tested in
accordance with the requirements of ASTM B 928
Make use of the filler metal selection chart for guidance
in choosing the most appropriate filler metal for your
particular application

Thank You For Attending

If you would like a copy of the
MAXAL technical brochure send
me an email with your mailing
address
Tony.anderson@millerwelds.com

Any Questions or Comments