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Metallurgical and Materials Transactions A
Published in: Metallurgical and Materials Transactions A 11/2009

01-11-2009

Mechanisms for Solidification Crack Initiation and Growth in Aluminum Welding

Authors: N. Coniglio, C.E. Cross

Published in: Metallurgical and Materials Transactions A | Issue 11/2009

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Abstract

In the present work, mechanisms are proposed for solidification crack initiation and growth in aluminum alloy 6060 arc welds. Calculations for an interdendritic liquid pressure drop, made using the Rappaz–Drezet–Gremaud (RDG) model, demonstrate that cavitation as a liquid fracture mechanism is not likely to occur except at elevated levels of hydrogen content. Instead, a porosity-based crack initiation model has been developed based upon pore stability criteria, assuming that gas pores expand from pre-existing nuclei. Crack initiation is taken to occur when stable pores form within the coherent dendrite region, depending upon hydrogen content. Following initiation, crack growth is modeled using a mass balance approach, controlled by local strain rate conditions. The critical grain boundary liquid deformation rate needed for solidification crack growth has been determined for a weld made with a 16 pct 4043 filler addition, based upon the local strain rate measurement and a simplified strain rate partitioning model. Combined models show that hydrogen and strain rate control crack initiation and growth, respectively. A hypothetical hydrogen strain rate map is presented, defining conceptually the combined conditions needed for cracking and porosity.
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Metadata
Title
Mechanisms for Solidification Crack Initiation and Growth in Aluminum Welding
Authors
N. Coniglio
C.E. Cross
Publication date
01-11-2009
Publisher
Springer US
Published in
Metallurgical and Materials Transactions A / Issue 11/2009
Print ISSN: 1073-5623
Electronic ISSN: 1543-1940
DOI
https://doi.org/10.1007/s11661-009-9964-4

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