Welding Aluminium

Background

Physically, chemically and mechanically aluminium is a metal like steel, brass, copper, zinc, lead or titanium. It can
be melted, cast, formed and machined much like these metals and it conducts electric current. In fact often the same
equipment and fabrication methods are used as for steel.

Light Weight

Aluminium is a very light metal with a specific weight of 2.7 g/cm3, about a third that of steel. For example, the use
of aluminium in vehicles reduces dead-weight and energy consumption while increasing load capacity. Its strength
can be adapted to the application required by modifying the composition of its alloys.

Corrosion Resistance

Aluminium naturally generates a protective oxide coating and is highly corrosion resistant. Different types of surface
treatment such as anodizing, painting or lacquering can further improve this property. It is particularly useful for
applications where protection and conservation are required.

Electrical and Thermal Conductivity

Aluminium is an excellent heat and electricity conductor and in relation to its weight is almost twice as good a
conductor as copper. This has made aluminium the most commonly used material in major power transmission
lines. High thermal conductivity of aluminium make is difficult to weld as compared to steel

Reflectivity

Aluminium is a good reflector of visible light as well as heat, and that together with its low weight makes it an ideal
material for reflectors in, for example, light fittings or rescue blankets.

Ductility

Aluminium is ductile and has a low melting point and density. In a molten condition it can be processed in a
number of ways. Its ductility allows products of aluminium to be basically formed close to the end of the product’s
design.

Impermeable and Odourless

Aluminium foil, even when it is rolled to only 0.007 mm thickness, is still completely impermeable (Preventing
especially liquids to pass or diffuse through) and lets neither light aroma nor taste substances out. Moreover, the
metal itself is non-toxic and releases no aroma or taste substance which makes it ideal for packaging sensitive
products such as food or pharmaceuticals.

Recyclability
Aluminium is 100 percent recyclable with no downgrading of its qualities. The re-melting of aluminium requires
little energy: only about 5 percent of the energy required to produce the primary metal initially is needed in the
recycling process.

Here are some of the most frequently asked questions regarding the welding of aluminum and their
answers from an expert:

1. Why is my aluminum weld much weaker than the parent material?

2. What type of shielding gas should I use for aluminum welding?
3. For TIG welding, what type of electrode is best for aluminum?
4. How much preheat should I use when welding aluminum?
5. What is the proper stress relieving practice for aluminum welds?
6. How can I tell different aluminum alloys apart?
7. How do I TIG weld two dissimilar thicknesses of aluminum?
8. How do I weld 7075?

1. Why is my aluminum weld much weaker than the parent material?

In steels a weld can be made as strong as the parent material, but this is not the case with aluminum. In almost all
instances, the weld will be weaker than the parent material. To further understand why this occurs, let's look at the
two classifications of aluminum alloys: heat treatable and non-heat treatable. The latter category is hardened only by
cold working which causes physical changes in the metal. The more the alloy is cold worked the stronger it gets.

But, when you weld an alloy that has been cold worked, you locally anneal the material around the weld so that it
goes back to its 0 tempered (or annealed) condition and it becomes "soft". Therefore, the only time in the non-heat
treatable alloys that you can make a weld as strong as the parent material is when you start with 0 tempered
materials.

With heat treatable aluminum alloys, the last heat treatment step heats the metal to approximately 400° F. But when
welding, the material around the weld becomes much hotter than 400° F so the material tends to lose some of its
mechanical properties. Therefore, if the operator doesn't perform post-weld heat treatments after welding, the area
around the weld will become significantly weaker than the rest of the aluminum - by as much as 30 to 40 percent. If
the operator does perform post weld heat treatments, the proprieties of a heat treatable aluminum alloy can be
improved.

The following is a guide as to which series of aluminum alloys are heat treatable and which are not:

Heat treatable series: 2000, 6000, 7000.

Non-heat treatable: 1000, 3000, 4000, 5000.

There are seven series of aluminum alloys. Each one is designated by the primary alloying element used to produce
that particular type of material. Additionally, we can divide the seven aluminum alloy series into the heat treatable
and non-heat treatable categories:

Series Primary Alloying Element

1xxx Aluminum - 99.00% or Greater (Non-Heat Treatable)

2xxx Copper (Heat Treatable)

3xxx Manganese (Non-Heat Treatable)

4xxx Silicon (Non-Heat Treatable)

5xxx Magnesium (Non-Heat Treatable)

6xxx Magnesium and Silicon (Heat Treatable)

7xxx Zinc (Heat Treatable)

2. What type of shielding gas should I use for aluminum welding?

For both TIG Welding (Gas Tungsten Arc Welding or GTAW) and MIG Welding (Gas Metal Arc Welding or
GMAW) use pure argon for aluminum materials up to ½" in thickness. Above ½" in thickness, operators may add
anywhere between 25 to 75 percent helium to make the arc hotter and increase weld penetration. Argon is best
because it provides more cleaning action for the arc than helium does and it is also less expensive than helium.

Never use any shielding gas that contains oxygen or carbon dioxide, as this will oxidize the aluminum.

3. For TIG Welding, what type of electrode is best for aluminum?

For most materials, including steel, a two percent thoriated tungsten electrode is recommended, but since aluminum
is welded with AC rather than DC, the electrical characteristics are different and the amount of energy put into the
tungsten electrode is higher when AC welding. For these reasons, pure tungsten or Zirconiated tungsten are
recommended for aluminum welding.

In addition, the electrode diameter for AC welding has to be significantly larger than when using DC. It is
recommended to start with an electrode that is 1/8" and adjust as needed. Zirconiated tungsten can carry more
current than pure tungsten electrodes. Another helpful hint for AC welding is to use a blunt tip - the arc tends to
wander around a pointed tip.

4. How much preheat should I use when welding aluminum?

While a little preheat is good, too much preheat can degrade the mechanical properties of the aluminum.

As was discussed earlier, the last heat treatment for heat treatable alloys is 400° F so if the operator preheats the
aluminum to 350° F and holds the temperature in that range while welding, the aluminum's mechanical properties
are changed.
For the non-heat treatable alloys such as the 5000 series, if the operator holds the temperature even in the 200° F
range - he or she can sensitize the material to stress corrosion cracking. In most cases, some preheat is acceptable to
dry the moisture away from the piece, but preheat should be limited.

Many inexperienced aluminum welders use preheat as a crutch. Since equipment for welding aluminum needs to
operate at higher capacities, many feel that preheat helps eliminate equipment limitations, but this is not the case.
Aluminum has a low melting point -- 1200° F compared to 2600° F to 2700° F for steel. Because of this low
melting point, many operators think they only need light duty equipment to weld the aluminum. But, the thermal
conductivity of aluminum is five times that of steel, which means that the heat dissipates very quickly. Therefore,
welding currents and voltages for welding aluminum are higher than they are for steel so operators actually need
heavier duty equipment for aluminum.

5. What is the proper stress relieving practice for aluminum welds?

When welding, the operator sets up residual stresses around the vicinity of the weld because the molten material
shrinks as it solidifies. Further, when the operator takes this welded structure and begins to remove material by
machining, it tends to distort and create dimensional instability. To avoid this in aluminum, operators perform stress
relieving by heating the material hot enough to allow the aluminum atoms to move around.

For steel, the stress relieving temperature is approximately 1050° F to 1100° F, but for aluminum, the proper stress
relieving temperature is 650° F. This means that in order for post weld stress relief on aluminum to be effective, the
material will have to be heated to a temperature where mechanical properties will be lost. For this reason, post weld
stress relief is not recommended for aluminum.

6. How can I tell different aluminum alloys apart?

There are quite a few different aluminum alloys and for proper and safe welding, you should know what alloy your
welding. If you don't, you can follow these general guidelines:

Extrusions are generally 6000 series alloys

Castings most often are a combination of aluminum/silicon cast -- some are weldable, others are not
Pieces of sheet, plate or bar are probably 5000 to 6000 series alloys

If you want to be precise, purchase an alloy tester kit that will help you determine the exact makeup of your alloy.

7. How do I TIG weld two dissimilar thicknesses of aluminum?

When an operator has two dissimilar thicknesses, he or she must set the parameters so that they are high enough to
TIG weld the thickest piece. When welding, favor the joint and put more of the heat on the thicker piece.

8. How do I weld 7075?

Most aluminum alloys are weldable, but there are a fair number of them that are not, including 7075 aluminum. The
reason 7075 is singled out in this example is that it is one of the highest strength aluminum alloys. When designers
and welders look for an aluminum alloy to use, many will start by reviewing a table that lists all of the aluminum
alloys and their strengths. But what those newcomers don't realize is that few of the higher strength aluminum
alloys are weldable - especially those in the 7000 and 2000 series - and they should not be used.

The one exception to the rule of never using 7075 for welding is in the injection molding industry. This industry will
repair dies by welding 7075 - but it should never be used for structural work.

Here are some simple guidelines to follow when choosing aluminum alloys:

Alloy Series Main Alloying Elements

1000 series Pure aluminum
2000 series Aluminum and copper. (High strength aluminum used in the aerospace
industry )
3000 series Aluminum and manganese. (Low- to medium-strength alloys, examples
of products using these alloys are beverage cans and refrigeration tubing)
4000 series Aluminum and silicon. (Most alloys in this series are either welding or
brazing filler materials)
5000 series Aluminum and magnesium. (These alloys are used primarily for
structural applications in sheet or plate metals - all 5000 series alloys are
weldable )
6000 series Aluminum, magnesium and silicon. (These alloys are heat treatable and
commonly used for extrusions, sheet and plate - all are weldable, but can
be crack sensitive. Never try to weld these alloys without using filler
metal)
7000 series Aluminum and zinc. (These are high strength aerospace alloys that may
have other alloying elements added)

Lincoln suggests that if you have a need to design something of high strength aluminum, look to a 5000 series high
magnesium alloy instead of a 2000 or 7000 series. The 5000 series alloys are weldable and will produce the best
results.

Conclusion

Lincoln Electric offers a full range of aluminum solutions from power sources, such as the Power Wave® 455M,
that are custom designed to perform with optimal arc characteristics on aluminum, to wire feeders, such as the
Cobramatic® push-pull system, for optimizing the feeding of the soft aluminum wire, to premium SuperGlaze®
aluminum wire, made with consistent chemistry for consistent performance. In addition to products, Lincoln prides
itself on being an aluminum welding expert and can be reached by either phone 1-888-935-3877 or e-mail to answer
your questions.
The first step in learning about welding aluminum is learning about the various alloys
themselves (cast and wrought)—the digits used in the aluminum designation system, the
properties of the various alloys, and the considerations in matching a filler metal to a base
material.

Selecting an appropriate filler alloy for welding aluminum differs from selecting a filler alloy for welding steels. In the
case of steel, selection is primarily a matter of matching the tensile strength of the filler metal to that of the base
alloy. For aluminum, many variables come into play, such as ease of welding, crack resistance, ductility, weld
strength, corrosion resistance, service temperature, and the effect of postweld heat treatment. Some of these
factors may be as important as, or more important than, tensile strength.
One of the first steps to successful aluminum welding, therefore, is to become acquainted with the many aluminum
alloys, their characteristics, and the aluminum identification system. Understanding this system will help you to
correlate the proper alloy with the service conditions of the finished component.
Aluminum Alloy Temper and Designation System In North America the Aluminum Association Inc. is responsible for
the allocation and registration of aluminum alloys. It recognizes more than 600 aluminum alloys—more than 400
wrought and more than 200 in the form of castings and ingots. The chemical composition limits for these alloys are
contained in the Aluminum Association's reference publications:

 International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought
Aluminum Alloys, also known as the Teal Book
 Designations and Chemical Com-position Limits for Aluminum Alloys in the Form of Castings and Ingots,
also known as the Pink Book

Aluminum alloys are grouped by the particular material's characteristics, such as its ability to respond to thermal and
mechanical treatment and the primary alloying element.

Wrought Alloy Designations

In the four-digit wrought aluminum alloy identification system, the first digit indicates the principal alloying element
(see Figure 1).
The second digit, if different from 0, indicates a modification of the specific alloy, and the third and fourth digits are
arbitrary numbers given to identify a specific alloy in the series. For example, in alloy 5183, the number 5 indicates
that it belongs in the magnesium series, the 1 indicates that it is the first modification to the original alloy 5083, and
the 83 identifies the particular alloy in the 5xxx series.
The only exception to this numbering system is in the 1xxx series, commonly called pure aluminums because they
are more than 99 percent aluminum. In this series, the last two digits provide the minimum aluminum percentage
above 99 percent. For example, alloy 1350 contains a minimum of 99.50 percent aluminum.

Cast Alloy Designations

The cast alloy designation system is based on three digits to the left of the decimal point and one to the right. The
first digit indicates the principal alloying element (see Figure 2). The second and third digits are arbitrary numbers
given to identify a specific alloy in the series.
The number following the decimal point indicates whether the alloy is a casting (.0) or an ingot (.1 or .2). A capital
letter prefix indicates a modification to a specific alloy.
For example, in alloy A356.0, the capital A indicates a modification of alloy 356.0. The number 3 indicates that it is
of the silicon plus copper and/or magnesium series. The 56 identifies the particular alloy within the 3xx.x series, and
the .0 indicates that it is a final-shape casting and not an ingot.

Aluminum Temper Designations

Two distinctly different types of aluminum exist within the wrought and cast series. These are heat-treatable (those
that can gain strength through the addition of heat) and non-heat-treatable alloys. This distinction can be important
when considering the effects of arc welding on these materials.
The 1xxx, 3xxx, and 5xxx series wrought aluminum alloys are non-heat-treatable and are strain-hardenable only.
The 2xxx, 6xxx, and 7xxx series wrought aluminum alloys are heat-treatable, and the 4xxx series consists of both
heat-treatable and non-heat-treatable alloys. The 2xx.x, 3xx.x, 4xx.x, and 7xx.x series cast alloys are heat-treatable.
Strain hardening generally is not applied to castings.
The heat-treatable alloys acquire optimum mechanical properties through thermal treatment, the most common
being solution heat treatment and artificial aging. In solution heat treatment, the alloy is heated to an elevated
temperature (around 990 degrees F) to put the alloying elements or compounds into solution. This is followed by
quenching, usually in water, to produce a supersaturated solution at room temperature.
Solution heat treatment is usually followed by aging. Aging is the precipitation of a portion of the elements or
compounds from the supersaturated solution in order to yield desirable properties. The aging process is divided into
two types: aging at room temperature, which is called natural aging, and aging at elevated temperatures, about 320
degrees F, which is called artificial aging. Many heat-treatable aluminum alloys are used for welding fabrication in
their solution heat-treated and artificially aged condition.
The non-heat-treatable alloys acquire optimum mechanical properties through strain hardening, which is induced by
cold working.
The temper designation system addresses these material conditions through an extension of the alloy numbering
system. This consists of a series of letters and numbers following the alloy designation number and connected by a
hyphen. Examples include 6061-T6, 6063-T4, 5052-H32, and 5083-H112 (see Figure 3).
Tempers are further identified with a suffix containing a letter H or a letter T. A letter H indicates strain hardening
and is followed by digits:
The first digit after the H indicates a basic operation:

 H1— Strain-hardened only

 H2—Strain-hardened and partially annealed
 H3—Strain-hardened and stabilized
 H4—Strain-hardened and lacquered or painted

The second digit after the H indicates the degree of strain hardening:

 Hx2—Quarter hard
 Hx4—Half hard
 Hx6—Three-quarters hard
  Hx8—Full hard
 Hx9—Extra hard

A letter T indicates thermal treatment; the T is followed by digits, which indicate a basic operation or a sequence of
operations:

 T1—Naturally aged after cooling from an elevated temperature-shaping process such as extruding
 T2—Cold-worked after cooling from an elevated temperature-shaping process and then naturally aged
 T3—Solution heat-treated, cold-worked, and naturally aged
 T4—Solution heat-treated and naturally aged
 T5—Artificially aged after cooling from an elevated temperature-shaping process
 T6—Solution heat-treated and artificially aged
 T7—Solution heat-treated and stabilized (overaged)
 T8—Solution heat-treated, cold-worked, and artificially aged
 T9—Solution heat-treated, artificially aged, and cold-worked
 T10—Cold-worked after cooling from an elevated temperature-shaping process and then artificially aged

Additional digits indicate stress relief, such as Tx51 or Txx51 (stress relieved by stretching) or Tx52 or Txx52 (stress
relieved by compressing).

Characteristics of the Aluminum Alloys

The main differentiator among the various series is the alloying element or elements that, in turn, influence many of
the series' characteristics.
1xxx. This series is non-heat-treatable and has an ultimate tensile strength from 10,000 pounds per square inch
(PSI) to 27,000 PSI. They are weldable, but because of their narrow melting range, specialized welding procedures
are necessary to produce acceptable welds. Their superior corrosion resistance makes them suitable in specialized
chemical tanks and piping; their excellent electrical conductivity makes them suitable for busbar applications. They
have relatively poor mechanical properties and are rarely used for general structural applications. These base alloys
often are welded with matching filler material or with 4xxx filler alloys, depending on the application and performance
requirements.
2xxx. This series is heat-treatable; the ultimate tensile strength range is from 27,000 PSI to 62,000 PSI. They have
copper content from 0.7 to 6.8 percent. They are high-strength, high-performance alloys often used for aerospace
and aircraft applications. They offer excellent strength over a wide range of temperatures.
Some are considered nonweldable by arc welding processes because of their susceptibility to hot cracking and
stress corrosion cracking; others are arc welded successfully with the correct welding procedures. These base
materials often can be welded with high-strength 2xxx series filler alloys designed to match their performance, but in
some cases they can be welded with 4xxx series fillers containing silicon or a combination of silicon and copper,
depending on the application and service requirements.
3xxx. These are non-heat-treatable alloys with ultimate tensile strength of 16,000 PSI to 41,000 PSI. The main
alloying element is manganese, which varies from 0.05 to 1.8 percent. They have moderate strength, good
corrosion resistance, good formability, and are suited for use at elevated temperatures. One of their first uses was
pots and pans, and they are the major component today for heat exchangers in vehicles and power plants. Their
moderate strength generally makes them unsuitable for structural applications. These base alloys are welded with
1xxx, 4xxx, and 5xxx series filler alloys, depending on their specific chemistry and particular application and service
requirements.
4xxx. This series consists of both heat-treatable and non-heat-treatable alloys. The ultimate tensile strength varies
from 25,000 to 55,000 PSI. They have silicon in amounts that vary from 0.6 to 21.5 percent. The silicon reduces the
melting point and improves fluidity when molten. These characteristics are desirable for filler materials used for
fusion welding and brazing; consequently, this series of alloys predominantly is used as filler material. Silicon by
itself makes aluminum non-heat-treatable; however, adding magnesium or copper results in a heat-treatable alloy.
Typically, these heat-treatable filler alloys are used only when a welded component is to be subjected to postweld
thermal treatments.
5xxx. This non-heat-treatable series has an ultimate tensile strength of 18,000 to 51,000 PSI. They have
magnesium additions from 0.2 to 6.2 percent. These have the highest strength of the non-heat-treatable alloys. In
addition, these alloys are readily weldable and therefore are used for a variety of applications such as shipbuilding,
transportation, pressure vessels, bridges, and buildings. Base alloys with less than approximately 2.5 percent
magnesium often are welded successfully with the 5xxx or 4xxx series filler alloys. The base alloy 5052 generally is
recognized as the maximum magnesium content base alloy that can be welded with a 4xxx series filler alloy.
Because of problems associated with eutectic melting and the resulting poor as-welded mechanical properties,
materials in this series at the high end of the magnesium scale should not be welded with 4xxx series fillers; 5xxx
filler alloys that generally match the base alloy composition are suitable for these metals.
6xxx. These heat-treatable metals have an ultimate tensile strength of 18,000 PSI to 58,000 PSI. They contain a
small amount of magnesium and silicon—around 1.0 percent. They are used widely throughout the welding
fabrication industry, predominantly in the form of extrusions, and incorporated in many structural components.
Solution heat treatment improves their strength. These alloys are solidification crack-sensitive, and for this reason
should not be arc welded autogenously (without filler material). The filler metal dilutes the base material, thereby
preventing hot cracking. They are welded with both 4xxx and 5xxx filler materials, depending on the application and
service requirements.
7xxx. These heat-treatable alloys have an ultimate tensile strength from 32,000 PSI to 88,000 PSI. The main
alloying element is zinc in amounts from 0.8 to 12.0 percent. They comprise some of the highest-strength aluminum
alloys and often are used in high-performance applications such as aircraft, aerospace, and competitive sporting
equipment. Like the 2xxx alloys, this series incorporates some alloys that are considered unsuitable candidates for
arc welding and others that often are arc welded successfully. The commonly welded alloys in this series, such as
7005, are welded predominantly with the 5xxx series filler alloys.

16
To appreciate the affect of arc welding on the heat-affected zone of various aluminum alloys, it is necessary to
evaluate the various types of aluminum alloys, how these alloys obtain their strength and the potential for changes
in strength after welding.

The various types of aluminum alloys

Considering the seven aluminum alloy series used for wrought alloys, the main alloying elements used for producing
each of the alloy series are immediately identifiable. Further examination of each of these elements’ effects on
aluminum is possible.

Series Primary Alloying Element

1xxx Aluminum - 99.00% or Greater

2xxx Copper

3xxx Manganese

4xxx Silicon

5xxx Magnesium

6xxx Magnesium and Silicon

7xxx Zinc

The principal effects of alloying elements in aluminum are as follows:

Pure Aluminum 1xxx - Although the 1xxx series are almost pure aluminum, they will respond to strain hardening,
especially if they contain appreciable amounts of impurities such as iron and silicon. However, even in the strain-
hardened condition, the 1xxx series alloys have very low strength when compared to the other series of aluminum
alloys. The most common applications for the 1xxx series alloys are aluminum foil, electrical buss bars, metalizing
wire and some chemical tanks and piping systems. These alloys are non-heat treatable.

Copper (Cu) 2xxx – The aluminum-copper alloys typically contain between 2 to 6% of copper, with small additions
of other elements. The copper provides substantial increases in strength and facilitates precipitation hardening.
These alloys include some of the highest strength heat treatable aluminum alloys. The most common applications
for the 2xxx series alloys are aerospace, military vehicles and rocket fins.

Manganese (Mn) 3xxx – The addition of manganese to aluminum increases strength to an extent through solution
strengthening. It improves strain hardening and does not significantly reduce ductility or corrosion resistance. These
are moderate strength non-heat treatable materials that retain strength at elevated temperatures. However, for
major structural applications, they are rarely used. The most common applications for the 3xxx series alloys are
cooking utensils, radiators, air conditioning condensers, evaporators, heat exchangers beverage containers,
residential siding, and handling and storage equipment.

Silicon (Si) 4xxx – The addition of silicon to aluminum reduces melting temperature and improves fluidity. Silicon
alone in aluminum produces a non-heat treatable alloy; however, in combination with magnesium, it produces a
precipitation hardening heat treatable alloy. Consequently, there are both heat treatable and non-heat treatable
alloys within the 4xxx series, The most common application for silicon additions to aluminum is the manufacturing of
aluminum castings. The most common applications for the 4xxx series alloys are filler wires for fusion welding and
brazing of aluminum.
Magnesium (Mg) 5xxx - The addition of magnesium to aluminum increases mechanical properties through solid
solution strengthening. Additionally, it improves their strain hardening ability. These alloys are the highest strength
non-heat treatable aluminum alloys and they are optimal and extensively used for structural applications. The 5xxx
series alloys are produced mainly as sheet and plate and only occasionally as extrusions. These alloys strain
harden quickly, therefore, they are difficult and expensive to extrude. Some common applications for the 5xxx series
alloys are truck and train bodies, buildings, armored vehicles, ship and boat building, chemical tankers, pressure
vessels and cryogenic tanks.

Magnesium and Silicon (Mg2Si) 6xxx – The addition of magnesium and silicon to aluminum produces the
compound magnesium-silicide (Mg2Si). The formation of this compound provides the 6xxx series their heat treat-
ability. The 6xxx series alloys extrude both easily and economically. For this reason, they are most often found in an
extensive selection of extruded shapes. These alloys form an important complementary system with the 5xxx series
alloy. The 5xxx series alloy used in the form of plate and the 6xxx series used in an extruded form are often joined
to the plate. Some of the common applications for the 6xxx series alloys are handrails, drive shafts, automotive
frame sections, bicycle frames, tubular lawn furniture, scaffolding, stiffeners and braces used on trucks, boats and
many other structural fabrications.

Zinc (Zn) 7xxx – The addition of zinc to aluminum (in conjunction with some other elements, primarily magnesium
and/or copper) produces heat treatable aluminum alloys of the highest strength. The zinc substantially increases
strength and permits precipitation hardening. Some of these alloys can be susceptible to stress corrosion cracking
and for this reason are not usually fusion welded. Other alloys within this series are often fusion welded with
excellent results. Some of the common applications of the 7xxx series alloys are aerospace, armored vehicles,
baseball bats and bicycle frames.

How aluminum alloys obtain their strength:

As seen above, aluminum alloys consist of both heat treatable and non-heat treatable types. The addition of alloying
elements to aluminum is the principal method used to produce a selection of different materials used in a wide
assortment of applications. The principle reason for adding the major alloying elements is to facilitate an
improvement in the alloys physical and/or mechanical characteristics. Typically, addition of primary alloying
elements to aluminum is to provide improvement in work hardening and/or precipitation hardening characteristics.

Work Hardening
Work hardening, used extensively to produce the strain-hardened tempers in the non-heat treatable aluminum
alloys, is an important process that increases the strength of materials that heat treatment cannot strengthen. This
process involves a change of shape brought about by the input of mechanical energy. As deformation proceeds, the
material becomes stronger but harder and less ductile. For example, the strain hardened temper of H18, full-hard
material is obtainable with a cold work equal to about a 75% reduction in area. The H16, H14 and H12 tempers
obtained with lesser amounts of cold working represent three-quarter-hard, half-hard, and quarter-hard conditions,
respectively.

Precipitation Hardening

Precipitation Heat treatment precedes solution heat-treating. Solution heat-treating is achieved by heating a material
to a suitable temperature, holding at that temperature for a long enough time to allow constituents to enter into solid
solution, then cooling rapidly to hold the constituents in solution. Usually this is followed by precipitation hardening,
or what is also termed artificial aging. This is achieved by re-heating the alloy to a lower temperature and holding it
at this temperature for a prescribed period. The result is to produce a metallurgical structure within the material that
provides superior mechanical properties. If, during heat treatment, the material is held at temperature for too long or
the temperature used is too high, the material will become over aged, resulting in a decrease in tensile strength. It is
important to recognize that the precipitation hardening process is both time and temperature controlled.

The Affect of Arc Welding on the Heat Affected Zone

In order to make a welded joint in an aluminum structure using the arc welding process melting of the base material
must occur. During the melting operation, heat transfers through conduction into the base material adjacent to the
weld. Typically, the completed weldment is divided into three distinct areas: the weld metal, the heat-affected zone
adjacent to the weld, and the base material beyond the HAZ that has been unaffected by the welding operation.
Because the HAZ will experience cycles of heating and cooling during the welding operation, arc welding on
materials which have been strengthened by work hardening or precipitation hardening, will change its properties
and may be extremely different than that of the original base alloy and the unaffected area of the base material (see
fig 1 and fig 2)

Non-Heat Treatable Alloys

What is important from a HAZ perspective is that aluminum alloys strengthened by strain hardening can be restored
to a full soft, ductile condition by annealing. Annealing eliminates the strain hardening, as well as the microstructure
that is developed because of cooled working. The heating of the HAZ, which takes place during the arc welding
operation, is sufficient to anneal the base material within the HAZ area. For this reason the minimum tensile strength
requirements for as-welded non-heat treatable alloys is based on the annealed strength of the base alloy. Typical
tensile strengths of non-heat treatable alloys in their tempered condition and as-welded are shown in table 1

Heat Treatable Alloys

In the case of the heat-treatable alloys, the HAZ will not be fully annealed. Typically, the HAZ is not maintained at an
adequate temperature for a sufficient period to anneal fully the HAZ. This does not suggest that experiences in a
reduction in strength in the HAZ will not occur. The affect on the HAZ of a heat treatable alloy that is welded in the
solution heat-treated and artificially aged condition is typically one of partially annealed and over-aged. This
condition is affected by the heat input during the welding operation. The general rule is, the higher the heat input,
the lower the as-welded strength. Typical tensile strengths of some of the heat treatable alloys in their temper
condition and as- welded are shown in table 2.

Summary

Dependant on the particular aluminum alloy type and its temper, there are often significant difference between the
tensile strength of the HAZ and the tensile strength of the unaffected area of the welded component. The reduction
in tensile strength of the HAZ under controlled conditions, particularly with the non-heat treatable alloys, can be
somewhat predictable. The reduction in tensile strength of the HAZ in the heat treatable alloys is more susceptible
to welding conditions and can be reduced below the required minimum requirement if excessive heating occurs
during the welding operation.
 Table 1
Typical Tensile Strength Properties of Groove Welds

Non-Heat Treatable Alloys

Base Alloy & Temper Base Alloy Tensile Strength - ksi As welded Tensile Strength - ksi

1060-H18 19 10

5052-H32 33 27

5052-H39 42 27

5086-H34 47 38

5086-H38 53 38

5083-H116 46 43

3003-H34 35 16

3004-H38 41 24

Table 2

Typical Tensile Strength Properties of Groove Welds

Heat Treatable Alloys

Base Alloy & Temper Base Alloy Tensile Strength - ksi As welded Tensile Strength - ksi

6063-T6 31 19

6061-T6 45 27

6061-T4 35 27

2219-T81 66 35

2014-T6 70 34

7005-T53 57 43
 Fig 1

Fig 2

POSTED IN ALUMINUM WELDING , TAGGED WITH GTAW, HELIARC, TIG

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