Inhibiting weld cracking in high-strength aluminium alloys

Yanan Hu, Shengchuan Wu (), Yi Guo, Zhao Shen (), Alexander M. Korsunsky, Yukuang Yu, Xu Zhang, Yanan Fu, Zhigang Che, Tiqiao Xiao, Sergio Lozano-Perez, Qingxi Yuan, Xiangli Zhong, Xiaoqin Zeng, Guozheng Kang and Philip J. Withers ()
Additional contact information
Yanan Hu: Southwest Jiaotong University
Shengchuan Wu: Southwest Jiaotong University
Yi Guo: Institute of Metal Research, Chinese Academy of Sciences
Zhao Shen: Shanghai Jiao Tong University
Alexander M. Korsunsky: University of Oxford
Yukuang Yu: Southwest Jiaotong University
Xu Zhang: Southwest Jiaotong University
Yanan Fu: Shanghai Synchrotron Radiation Facility (SSRF), Shanghai Advanced of Sciences
Zhigang Che: Science and Technology on Power Beam Processes Laboratory, AVIC Manufacturing Technology Institute
Tiqiao Xiao: Shanghai Synchrotron Radiation Facility (SSRF), Shanghai Advanced of Sciences
Sergio Lozano-Perez: University of Oxford
Qingxi Yuan: Beijing Synchrotron Radiation Facility (BSRF), Chinese Academy of Sciences
Xiangli Zhong: The University of Manchester
Xiaoqin Zeng: Shanghai Jiao Tong University
Guozheng Kang: Southwest Jiaotong University
Philip J. Withers: The University of Manchester

Nature Communications, 2022, vol. 13, issue 1, 1-9

Abstract: Abstract Cracking from a fine equiaxed zone (FQZ), often just tens of microns across, plagues the welding of 7000 series aluminum alloys. Using a multiscale correlative methodology, from the millimeter scale to the nanoscale, we shed light on the strengthening mechanisms and the resulting intergranular failure at the FQZ. We show that intergranular AlCuMg phases give rise to cracking by micro-void nucleation and subsequent link-up due to the plastic incompatibility between the hard phases and soft (low precipitate density) grain interiors in the FQZ. To mitigate this, we propose a hybrid welding strategy exploiting laser beam oscillation and a pulsed magnetic field. This achieves a wavy and interrupted FQZ along with a higher precipitate density, thereby considerably increasing tensile strength over conventionally hybrid welded butt joints, and even friction stir welds.

Date: 2022
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DOI: 10.1038/s41467-022-33188-x

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