Comparison of Mechanical, Fatigue, and Corrosion Properties of Fusion-Welded High-Strength AA6011 Alloy Using Three Filler Wires

Processes Pub Date : 2024-06-07 DOI:10.3390/pr12061172
Mohamed Ahmed, M. Javidani, A. Maltais, X.-Grant Chen
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Abstract

In this study, the welding performance of three filler wires, ER4043, ER5356, and the newly developed FMg0.6, were systematically investigated in the gas metal arc welding of high-strength AA6011-T6 plates. An extensive analysis of the microstructural evolution, mechanical properties, fatigue resistance, and corrosion behavior of different weldments was conducted. The ER4043 and FMg0.6 joints exhibited finer grain sizes in the fusion zone (FZ) than the ER5356 joint. The as-welded ER5356 and FMg0.6 joints exhibited higher hardness and tensile strength values than the ER4043 joint. The FMg0.6 joint demonstrated the highest mechanical strength among all of the joints with superior fatigue resistance under both the as-welded and post-weld heat treatment (PWHT) conditions. In the as-welded state, the ER5356 joint exhibited the lowest corrosion resistance, attributed to the precipitation of β-Al2Mg3 at the grain boundaries. The FMg0.6 joint, characterized by a high-volume fraction of eutectic Mg2Si in the as-welded state, exhibited a higher corrosion rate than that of the ER4043 joint. However, the PWHT effectively improved the corrosion resistance of the FMg0.6 joint. Given its excellent tensile properties, superior fatigue properties, and satisfactory corrosion resistance, particularly with PWHT, the newly developed FMg0.6 filler has emerged as a promising candidate for welding high-strength 6xxx alloys.
使用三种填充线熔焊高强度 AA6011 合金的机械、疲劳和腐蚀特性比较
本研究系统研究了 ER4043、ER5356 和新开发的 FMg0.6 三种填充焊丝在高强度 AA6011-T6 板材的气体金属弧焊中的焊接性能。对不同焊件的微观结构演变、机械性能、抗疲劳性和腐蚀行为进行了广泛分析。与 ER5356 焊点相比,ER4043 和 FMg0.6 焊点在熔合区(FZ)的晶粒尺寸更细。焊接后的 ER5356 和 FMg0.6 接头的硬度和拉伸强度值均高于 ER4043 接头。在所有接头中,FMg0.6接头的机械强度最高,在焊接状态和焊后热处理(PWHT)条件下的抗疲劳性也更出色。在焊接状态下,ER5356 接头的耐腐蚀性能最低,这归因于晶界处β-Al2Mg3 的析出。FMg0.6 接头的特点是在焊接状态下共晶 Mg2Si 的体积分数较高,其腐蚀速率高于 ER4043 接头。然而,PWHT 能有效提高 FMg0.6 接头的耐腐蚀性。新开发的 FMg0.6 填充剂具有优异的拉伸性能、卓越的疲劳性能和令人满意的耐腐蚀性能,尤其是在 PWHT 条件下,因此有望成为焊接高强度 6xxx 合金的理想材料。
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