Guide

for

Aluminum

Welding焊工對(duì)優(yōu)質(zhì)鋁焊絲的選擇作為一種優(yōu)質(zhì)的填充金屬解決方案，霍巴特鋁線由一個(gè)擁有數(shù)十年鋁填充金屬專業(yè)知識(shí)的團(tuán)隊(duì)支持和制造。它由最先進(jìn)的設(shè)施生產(chǎn)，完全圍繞鋁線生產(chǎn)而建，擁有定制的設(shè)備和專有的工藝和生產(chǎn)技術(shù)。Hobart’s

expertise

and

customized,innovativemanufacturing

processes

provide

aluminum

weldwire

with

excellent

soft-start

characteristics

andminimalburn

back.

Manual

applications

achieveagreater

weld

bead

quality.

Hobart

wire

alsofeatures

superiorfeedabilitywith

reduced

birdnesting,

extendedlinerand

contacttip

life,

andexcellent

x-ray

quality.Hobart

has

gainedrecognition

in

the

industryas

a

premium

aluminum

filler

metal

brand

withunmatched

product

quality,

reliability

andperformance.

As

a

part

of

the

ITW

WeldingNorth

America

portfolio,

Hobart

wire

and

feedingsolutions

will

be

combined

with

Miller,Bernard,Tregaskiss,

and

Weldcraft

to

create

the

bestaluminum

welding

systems

available.Technical

Assistance:

877-629-2564To

Place

An

Order:

800-424-1543ITW

Welding*Hobart

Brothers

LLC

disclaims

liability

for

anyinjury

to

persons

or

to

property,

or

other

damagesof

any

nature

whatsoever,

whether

special,indirect,

consequential,

or

compensatory,

directly

or

indirectly

resulting

from

the

publication,

use

of,

or

reliance

on

this

Guide

for

Aluminum

Welding.Hobart

Brothers

Company

also

makes

no

guarantee

or

warrantyasto

the

accuracy

or

completeness

ofany

information

published

herein.這不僅僅是創(chuàng)新的制造方法和技術(shù)，使霍巴特的產(chǎn)品“一流”。將產(chǎn)品交付到客戶手中的每一個(gè)方面的質(zhì)量和對(duì)細(xì)節(jié)的細(xì)致關(guān)注也是重中之重。這是一個(gè)眾所周知的事實(shí)，鋁需要特殊的程序與工作，因此鋁焊接材料必須能夠滿足所有要求?；舭吞禺a(chǎn)品的關(guān)鍵標(biāo)準(zhǔn)如下:極高的清潔度(能夠超過(guò)AWS孔隙率標(biāo)準(zhǔn))Outstanding

feedabilitySuperior

arc

stabilitySuperior

arc

startsExcellent

welder

appealRepeatability

and

consistencyWire

diameter

control

(1/10thof

allowed

AWSspecification)All

these

features

available

in

awiderange

of

alloysPlant

and

product

certifications

ISO

9001,

AWS,

CWB,

ABS,

ASME,

CE,

VdTUV

and

DBThe

quality

does

not

end

here,

the

productthen

needs

to

be

packaged

anddeliveredto

the

customer.To

ensure

the

product

arrives

in

the

samecondition

when

it

left

the

factory,

greatdetailhas

been

givento

the

packaging.

Some

of

the

unique

features

are

as

follows:Spools

and

Baskets

(MIG):A

sturdy

12”

spool

double

walled

reusable

box

with

top

entryNo

taping

of

the

box

flap

due

to

snug

fitting

closureA

sturdy

wire

basket

spool;

the

strongest

in

the

industryHeavy

weight

plastic

bag

for

better

atmosphericprotection8”

5

lb.,

12”

16

lb.

and

22

lb.

plastic

spools

availableUnique

alloy

selection

guide

on

side

of

all

boxes

(MIG

and

TIG)Straight

Lengths

(TIG):Revolutionary

TIG

box

with

zipper

style

end

cap

for

removal

of

a

few

rods

then

replaced

for

protection

Inner

linerinTIG

box

adds

to

sturdiness,

provides

snug

fit,

rods

stretch

wrappedinbundleseliminates

moisture

and

fretting

corrosionMaster

TIG

carton

holds

4

boxesDrums

300#

drum,

100#drum

and

50#

ergo

pacdrumprovidetanglefree

feeding

with

minimalutilization

ofdispensing

systemsMulti-sided

for

extra

sturdiness,

adapts

to

most

currently

available

conesDouble

walled

with

plastic

sealable

bagbetween

walls

for

moisture

protection

Unique

self

contained

pallet

for

maneuverability

eliminates

use

of

lifting

straps

which

can

damagedrums

and

wireTwo

individual

drums

perskidConsidering

all

the

above

including

an

extensive

range

of

welding

filler

metals

with

the

unparalleledtechnical

expertise

andservices,Hobart

Aluminum

is

the

only

choice

for

your

aluminum

welding

solutions.The

Way

–

Product

DifferentiationALLOY110040434047414549435356555451835556MIG/TIGYesYesYesYesYesYesYesYesYesHobart

Guide

for

Aluminum

Welding為鋁材設(shè)計(jì)工程師，工藝工程師和焊工提供技術(shù)支持所有的商業(yè)焊接作業(yè)都應(yīng)該有書(shū)面的焊接程序規(guī)范(WPS)。本手冊(cè)提供了確定生產(chǎn)可靠WPS和實(shí)現(xiàn)成功焊接結(jié)果所需的關(guān)鍵技術(shù)要素的指導(dǎo)。以下使用典型焊接程序規(guī)范(WPS)的流程作為其組織的指導(dǎo)方針，第3頁(yè)顯示了WPS表格的示例。Index:Page

3

WPS

Sample

FormPage

4

Alloy

and

Temper

DesignationsPage

5

Alloy

and

Temper

ApplicationsPage

6

Heat

Treatable

and

Non-Heat

Treatable

AlloysPage

7

Welded

Properties

of

5xxx

and

6xxxSeriesBaseMetalsPage

8

Guidelines

For

Selecting

the

Most

AppropriateFiller

Metal

(4043

or

5356)Page

9

MAXAL

Mig?R4943

and

MAXALTig?R4943Page

10

Selecting

the

Correct

Filler

Metal

toMatchAnodized

ColorNon-Weldable

Aluminum

Base

Metals(ArcWelding)Page

11

Nominal

Compositions

of

Wrought

Alloys

andTypical

Physical

PropertiesPage

12

Cleaning

the

Base

Metal

beforeWeldingMetal

Storage

and

Weld

Joining

Preparation

-Do’s

and

Don’tsPage

13

Weld

BackingPreheating

and

Interpass

TemperaturesPost-Weld

Heat

Treatment

and

AgePage

14

Electrodes

for

Aluminum

TIG

WeldingShielding

GasesUsedfor

MIG

and

TIG

WeldingPage

15

MIGand

TIG

JointGeometriesMIG

Equipment

Set-Up

ParametersPage

16

Typical

MIGParameters

for

Groove

Welds

InAluminumPage

17

Typical

MIG

Parameters

for

Fillet

Welds

InAluminumPage

18

Typical

TIG

Parameters

for

Groove

Welds

InAluminumPage

19

Typical

TIG

Parameters

for

Fillet

Welds

InAluminumPage

20

Preferred

Mode

of

Metal

Transfer

to

be

UsedWhen

MIG

Welding

AluminumPage

21

Pulsed

Spray

TransferMIG

Welding

of

AluminumPage

22

Obtaining

a

Stable

Arc

and

Eliminating

ErraticFeeding

and

BurnbacksPurchasing

Contact

Tips

and

MaintenanceSuggestionsPage

23

Drive

Roll

Design

and

Wire

FeedabilityPage24Weld

Joint

PorosityPage

25

Tips

for

Reducing

Weld

Joint

PorosityPage

26

Calculation

of

Dew

PointPage

27

How

to

Avoid

Cracking

in

Aluminum

AlloysPage

29

Weld

Discoloration,

Spatter

and

Black

SmutPage

30

Weld

Bead

Root

Penetration

and

FusionPage

31

Weld

Bead

Contour

andPenetrationGuidelines

For

Elevated

Temperature

Applications

Page

32

Solving

Weld

Profile

ProblemsPage33

The

Guided

Bend

TestPage

34

The

Transverse

Tension

TestPage35

Chemistry

Certifications:

AWS

ClassificationsPage

36

American

Welding

Society

Control

DocumentsPage

37

Welding

Design

Information

and

TechnicalAssistancePage

38

Conversion

TablesPage39

Traceability

of

Electrode

and

RodCertifications

and

Society

ApprovalsQuality

of

Electrode

andRodCustomer

SupportPage

40

Advanced

Aluminum

Welding

Technology

SeminarPage

41

Miller

SolutionsPage

42

Industrial

Aluminum

MIGSolutionsIndustrial

Aluminum

TIG

SolutionsThe

MAXAL

CommitmentWeld

Preparation

&

TreatmentsProblem

SolvingBase

MetalSpecificationsFiller

MetalWelding

ProceduresWelding

Procedure

SpecificationInformation

SourcesMiller

Solutions

Made

for

AluminumWeldingProcedureSpecificationWeldingProceduresFiller

MetalWeld

Preparation&

TreatmentsBase

MetalProblemSolvingSpecificationsInformationSourcesSpecification

No.

Date

Date

Approved

Approved

Revisions

PQR

Numbers

Certification

Specifications

&

Codes

AWS

M-No.

Alloy

Temper

Section

ThicknessAWSF-No.

AWSClass

Welding

wirediameter

Welding

wire

type:

MIG

TIG

Cleaning:Oxideremoval

Hydrocarbon/contaminantremoval

Etch

Solvent

Wash

Interpass

cleaning: Yes

No

Interpasscleaningmethod

Preheat:Yes

No

Preheattemperature

Interpasstemperaturelimit

Backing:Type

Permanent

Remove

Post-Weld

Heat

Treatment&

Age:Original

temperSolution

temp.Time

attemp.

Quench

type

&

temp.

Age

temp.Age

time

The

Welder’s

ChoiceforQuality

Aluminum

Weld

WireWelding

Procedure

SpecificationWeldingProcedureSpecificationWeld

Preparation

&

TreatmentsBase

MetalSpecificationsFiller

MetalWelding

Procedures3Process:

MIG

TIG

Shielding

Gas:Type

FlowRate

Mixture

Gas

Cup

Size

Weld

Description:

Groove

Fillet

WeldPosition:

Progression:

Weld

Pass

Type:Stringer

Oscillation

Weave

Other

Back

Gouging:Yes

No

Method

Welding

Pass

Data:Passno.WeldingprocessAmpsVoltsTravelspeedWelding

SequenceSketch:Weld

Profile

Picture:Aluminum

Alloy

Tempers

-

Aluminum

Association

Designations自由加工狀態(tài)退火狀態(tài)加工硬化狀態(tài)H1

-僅加工硬化H2

-加工硬化后不完全退火H3

-加工硬化后穩(wěn)定化處理H4

-加工硬化后涂漆處理固溶熱處理狀態(tài)不同于FOH的狀態(tài)的熱處理T1

-高溫成型+自然時(shí)效T2

-高溫成型+冷加工+自然時(shí)效T3

-固溶處理+冷加工+自然時(shí)效T4

-固溶處理+自然時(shí)效T5

-高溫成型+人工時(shí)效T6

-固溶處理+人工時(shí)效T7

-固溶處理+過(guò)時(shí)效T8

-固溶處理+冷加工+人工時(shí)效T9

-固溶處理+人工時(shí)效+冷加工T10

-高溫成型+冷加工+人工時(shí)效TX51

-拉力消除應(yīng)力TX52

-壓縮消除應(yīng)力Base

MetalBase

Metal4FOHWTAlloy

And

Temper

DesignationsAluminum

Alloy

Compositions

-

AluminumAssociation

Numbering

SystemWrought

Alloys

Casting

Alloys

Principal

Alloying

Elements1xx.x2xx.x3xx.x4xx.x5xx.x6xx.x7xx.x8xx.x9xx.x99.00%

Minimum

AluminumCopperSilicon

+

Copper

and/or

MagnesiumSiliconMagnesiumUnused

SeriesZincTinOther

ElementsAlloyAnd

Temper

Applications5最常用的鍛造鋁基金屬鍛造合金典型溫度應(yīng)用和特點(diǎn)1xxx

(pure)1350-

F,

-OElectrical

bus

bars1100-O,

-H14Formability

(deep

drawing

etc.),

corrosion

resistance

(chemical

tanks)2xxx

(Cu)2219-T6High

strength-to-weight

ratio

(aerospace),

large

service

temperature

range3xxx

(Mn)3003-O,

-H12Formability

and

high

temperature

service

(heat

exchangers,

cookware)5xxx

(Mg)5052-O,

-H34Formability,

corrosion

resistance,

and

low

cost

(roll

forms,

auto,

trailers,truck

trailer

sheeting)5454-O,

-H34Elevated

temperature

applications

(wheels)5086-H32,

-H34Strength

and

toughness

(shipbuilding,

boats)5083-H32High

strength,

good

saltwater

corrosion

resistance

(shipbuilding),

cryogenic

application5456-H32High

strength-to-weight

ratio

(pressure

vessels,

tanks)6xxx

(Mg/Si)6061-T6,

-T651High

strength

and

toughness

(truck

trailer,

rail

cars)6063-T5Strength

and

good

anodizing

properties

(architectural

applications,

automotive

trim)6005-T5Cost

efficient

extrusions

(auto,

architectural

applications)

6009

61117xxx

(Zn)

7005

Copper-free

7xxx

alloys

which

are

good

for

extrusions.

7021

-T53,

-T63

Good

toughness

and

formability.

(automotive,

truck,

ships

railings,

7029

bumper

supports,

sports

products

such

as

bats,

bikes

etc.)7146Note:

Alloys

2024,

7075

and

7050

are

considered

non-weldable

by

the

arc

welding

process.

See

page

9.Most

Commonly

Used

Cast

Aluminum

AlloysCasting

Alloys

Non-Heat

Typical

Tempers

-Treatable

Heat

TreatApplications

andFeatures2xx.xable201.0

Limited

Weldability206.0

Limited

Weldability224.0

Limited

Weldability3xx.x

(Si+Cu

and/orMg)319.0

x

Elevated

temperature

strength

(auto

pistons)333.0

x

Elevated

temperature

strength

(diesel

pistons)354.0

x

(auto

accessories,

crank

cases)C355.0x(aircraft,missiles)A356.0

(356.0)

xGeneral

purposestructuralA357.0xHigh

strength

(aerospace)359.0

xHigh

impact

strength

(aircraft

structural)380.0

xGeneral

purpose4xx.x

(Si)443.0

xPressure

tight

(marine,

valves)A444.0x5xx.x

(Mg)511.0

xGood

anodizing

properties

(architectural)(fittings,

cooking

utensils)512.0

x513.0

x514.0

xExcellent

corrosion

resistance

(chemical

processing,

marine)7xx.0

(Zn)710.0

xGood

brazing

characteristics(general

purpose,

corrosion

resistantapplications)712.0

xBase

MetalHeat

Treatable

And

Non-Heat

Treatable

Alloys本節(jié)討論了可熱處理與不可熱處理鋁合金在焊接前后的性能。這是任何試圖選擇最佳基材合金和回火以及連接它們的正確填充材料的人都要關(guān)注的領(lǐng)域。正是在這一領(lǐng)域，制造商很難在生產(chǎn)中實(shí)現(xiàn)一致的機(jī)械性能和無(wú)缺陷焊接件。出于討論的目的，本節(jié)將限制對(duì)話框?qū)?xxx和5xxx系列合金進(jìn)行比較：The

6xxx

series

base

metals

have

low

alloy

content

and

are

easy

for

mill

product

fabricators

to

form

intoextrusions,

tubing,

forgings

and

other

shaped

products

and

then

to

heat

treat

to

obtain

high

mechanicalproperties,

making

them

economical

to

produce.

The

5xxxseries

base

metals

have

high

alloy

content

andbecause

of

their

strain

hardening

and

higher

flow

stresscharacteristics

are

more

costly

to

fabricate

into

shapes.However

the

5xxxseriesbase

metals

are

economically

rolled

into

sheet

and

plate

and

roll

formed

intoshapeswhen

specific

shapes

are

desired.The

6xxx

series

base

metals

obtain

their

maximum

mechanical

properties

through

heat

treatment

and

aging.

Thealuminum

metal

matrix

is

strengthened

by

the

precipitation

of

the

alloying

elements

as

intermetallic

compoundswhose

size

and

distribution

throughout

the

matrix

iscarefully

controlled

through

precise

thermal

operations.When

the

6xxx

series

base

metals

are

welded,

the

microstructure

in

the

HAZ

is

degraded

and

themechanicalproperties

are

typically

reduced

by

30

-

50%.

Figure

1

on

page

7

shows

that

6061

and

its

most

common

fillermetal

4043

both

have

a

typical

annealed

tensile

strength

of

around

19

ksi.

Depending

on

the

heat

input

duringthe

welding

operation,

the

base

metal

can

be

fully

annealed

for

some

distance

from

the

weld,

especially

in

areasbeing

weld

repaired.The

5xxx

seriesbase

metals

obtain

their

maximum

mechanical

properties

through

alloying

element

solid

solutionstrengthening

and

additional

strength

is

gained

from

cold

working.

The

welding

operation

does

not

affect

the

solid

solution

strengthening

of

the

base

metal,

only

the

cold

working

portion

of

the

strength

is

lost

in

the

heataffected

zone

transforming

it

to

the

annealed

condition.

Figure

1

on

page

7

shows

that

the

typical

annealed

tensile

strength

of

5083

base

metal

is

43

ksi.Figure

1

on

page

7

compares

the

loss

of

strength

in

the

heat

affected

zone

of

welded

6061-T6

and

5083-H321wrought

base

metals.Figure2

on

page

7

showsthe

lossof

strength

in

the

heat

affected

zone

of

the

as-welded

6061-T4

and

-T6

basemetals

compared

with

post-weld

aging.The

chart

on

page

7

shows

thebasicalloying

elements

and

typical

ultimate

tensile

strengths

in

the

non-weldedand

as-welded

conditions

for

the

most

frequently

welded

6xxx

and

5xxx

series

base

metals.

The

charts

illustrateand

are

supported

by

the

following

important

points:The

lossof

as-welded

strength

in

the

5xxxbasemetalsissignificantly

lessthan

that

of

the

6xxxbasemetals.The

6xxx

base

metal

properties

shown

are

dependent

on

a

minimum

of

20%

dilution

of

6xxx

base

metal

intothe

4043

filler

metal

weld

pool.

The

5xxxbasemetals

when

welded

with

5xxx

filler

metals

are

not

dependenton

dilution.The

6xxxbase

metals

have

30%higher

thermal

conductivity

than

the

5xxxbase

metals

making

it

more

difficultto

produce

consistent

quality

welds

in

the

6xxxbase

metals.

Therefore

6xxx

basemetals

require

higher

heatinput

to

achieve

penetration

and

this

can

result

in

increased

distortion

of

the

weldedstructure.6xxx

base

metals

welded

with

5xxx

filler

metals

are

more

solidification

crack

sensitive

than

5xxx

base

metalswelded

with

5xxx

filler-metals.

See

page

10.The

as-welded

mechanical

properties

of

the

6xxx

base

metals

are

very

sensitive

to

welding

variables

such

asheat

input

and

joint

design

whereas

the

5xxx

base

metals

are

far

less

sensitive

to

these

variables,makingthe

5xxx

as-welded

results

much

more

controllable.As-welded

5xxx

basemetals

welded

with

5xxx

filler

metals

have

higher

ductility,

toughness,

and

crackpropagation

resistance

than

as-welded

or

post-weld

heat

treated

and

aged

6xxx

base

metals

weldedwith

4043.Base

Metal6Welded

Properties

Of

5xxx

And

6xxx

Series

Base

MetalsBase

Metal7Un-welded

&

welded

mechanical

properties

for

the

most

frequently

welded

6xxx

&

5xxx

series

base

metals.Figure

1Typical

properties

of

6061-T6

as

weldedwith

three

different

heat

inputsvs.

Figure

25083-H321

as

welded

with

high

or

low

heat

Typical

properties

of

6061-T4

&

T6Base

Metal&Temper%Si%MgTypical

UTS

(non-HAZ)ksiTypical

UTS(welded)ksiMin.

Expected

UTS

(welded)ksiMin.

Expected

UTS

(welded)

as

a%

of

Typical

UTS

(non-HAZ)%Heat

Treatable

6xxx

Base

Metals6061T60.61.045272453T4

(PWA)45373271T6

(PWA)43332761T6

(PWH&A)454438846063T60.40.735201754(PWA)

-

post-weld

aged(PWH&A)-

post-weldheattreated

and

agedNon-Heat

Treatable

5xxx

Base

Metals5052H322.535282571H34382825665454H342.7443531705086H344.0473935745083H116

&

H3215.0464340875456H1165.151464282Guidelines

For

Selecting

The

Most

Appropriate

Filler

Metal

(4043/4943

or

5356)Selecting

the

correct

filler

alloy

for

aluminum

is

based

on

the

operating

conditions

of

the

finished

welded

component.It

is

therefore

essential

to

have

the

answers

tosomebasic

questions

prior

to

the

selection

of

the

most

appropriatefiller

metal.What

is

the

aluminum

base

metaldesignation?Will

the

welded

component

be

exposed

to

sustained

elevated

temperature?Will

the

completed

weldment

be

subjected

to

post

weldanodizing?Will

shear

strength,

ductility,

and

toughness

be

of

prime

consideration?Is

post-weld

heat

treatment

to

be

performed?Alloys

4043/4943

and

5356

are

used

in

over

85%

of

all

aluminum

weldments.

If

the

technical

requirements

of

theweld

can

be

met

with

either

4043/4943

or

5356,

use

one

of

these

two

alloys

because

they

are

readily

availableand

are

the

least

expensive

to

purchase.

Also

considerusingthe

largest

recommended

diameter

wire

because

thelarger

sizes

are

also

lessexpensive.When

welding

the

5xxx

and

6xxx

series

base

metals

the

following

considerations

should

be

made

when

selectingthe

most

appropriate

filler

metal:For

6xxx

series

base

metals,

and

5xxxseries

base

metals

containing

up

to

2.5%

(nominal)

Magnesium

useeither

4043/4943

or

5356.For

5xxx

seriesbasemetals

containing

more

than2.5%(nominal)

Magnesiumuse5356filler

metal

and

do

notuse

4043/4943

filler

metal.For

good

anodized

color

matching

use5356.For

higher

ductility

and

toughnessuse5356.This

will

increase

resistance

to

crack

propagation.For

long

term

elevated

temperature

exposure

above

150°F

use

5554

or

4043/4943.

Do

not

use

5356.For

higher

shear

strength

use

5356

or

4943.

A

rule-of-thumb

is

that

it

takes

three

fillet

passes

of

4043

toequal

the

shear

strength

of

one

pass

of

5356.For

reduction

of

termination

and

shrinkage

cracking

use

4043/4943

or

4047.For

reduction

of

welding

distortion

use

4043/4943

or

4047.For

brighter

welds

with

less

welding

“smut”

use

4043/4943.For

better

feedability

through

the

welding

gun

use

5356.

5356

is

twice

as

stiff

as

4043/4943

and

thereforefeeds

better.

However,

MAXAL’s

4043/4943

has

excellent

feedability.Note:

For

more

detailed

information

on

filler

metal

selection

refer

to

the

Hobart

selection

chart

in

the

back

of

this

book.Filler

Metal8Filler

Metal9Filler

MetalApplications:Current

4043

and

4643

Applications,

Welding

1xxx,

3xxx,

4xxx,

5xxx

series

withup

to2.5%(nominal)

Magnesium

(Mg)

suchas5052&6xxx

seriesbasemetals.(Refer

to

the

Hobart

Aluminum

filler

metal

selection

chart

for

further

guidance

in

selectingfiller

metals

for

welding

specific

base

metals.)Automotive/motorcycle

framesAerospace

hardwareWheelsShip

decksFurniturePost

weld

age,

post

weld

heat

treat

&

age

applicationsSports

products

-

scooters/bicyclesGeneral

repair

and

maintenanceAlloy

356

CastingsLadders

and

framesMaxalMig?

ER4943

and

MaxalTig?

R4943A

25%

increase

in

tensile

+

shear

strength

and

50%

increase

in

yield

strengthAlloy4943

filler

metal

was

designed

to

provide

ahigh

strength

solution

with

the

easeof

welding

and

otheradvantages

of

4043.

Alloy

4043

filler

metal

is

a

popular

aluminum/silicon

filler

alloy

for

general

purpose

weldingapplications.

Alloy

4943

filler

metal

was

formulated

to

be

welded

with

the

same

weld

procedure

specifications

as4043

and4643,anddoes

not

depend

upon

dilution

from

thebasemetal

during

welding

to

increase

the

strengthof

the

weld

deposit,

while

maintaining

thesame

excellent

corrosion

characteristics,

low

melting

temperature,low

shrinkage

rate,

higher

fluidity,

and

low

hot

cracking

sensitivity.

Welds

exhibit

low

welding

smut

and

lowdiscoloration.

4943

is

heat-treatable

and

exhibits

strength

levels

superior

to

4043

and

4643

in

post

weld

ageand

post

weld

heat

treat

andageconditions.Testing

has

shown

that

4943

will

typically

provide

25%

improved

tensile

and

shear

strength

as

50%

improvedyield

strength

over

4043

in

the

as-needed

condition.Strength

Comparison,

4043

vs.

4943(All

weld

metal,

GMAW,

no

base

metal

dilution)Fillet

Weld

Strength:The

most

important

benefit

of

4943

is

to

provideconsistently

higher

strength

fillet

welds.

There

are

farmore

fillet

welds

than

groove

welds

used

in

structuralwelded

components

and

unlike

full

penetration

groove

weldtransverse

tensile

strength,

which

is

controlled

by

the

basemetal

HAZ,

fillet

weld

shear

strength

is

directly

controlledby

the

strength

of

the

filler

metal

usedduring

welding.

Fillermetal

shear

strength

is

proportional

to

filler

metal

tensilestrength.

Typical

shear

strength

for

4943

is

greater

than15.5

ksi

(4043published

valueis

11.5

ksi).Guidelines

For

Elevated

Temperature

ApplicationsAlcoa

research

engineers

discovered

that

stress

corrosion

cracking

(SCC)

in

5xxxseries

alloys

can

be

encounteredwhen

used

in

elevated

temperature

applications.

The

research

and

resultant

field

performance

data

showsthat

5xxx

series

alloys

with

magnesium

contents

above

3%are

susceptible

toSCCwhen

exposed

to

prolongedtemperatures

between

150

and

350

degrees

F.

With

prolonged

exposure

to

these

temperatures,

precipitates

canform

in

the

grain

boundaries

that

are

highly

anodic

to

the

aluminum-magnesium

matrix.

Itis

this

continuous

grainboundary

network

of

precipitates

that

produces

susceptibility

tostresscorrosion

cracking

(SCC)

and

the

potentialfor

premature

componentfailure.Base

metal

5454

was

specifically

developed

by

Alcoa

for

good

strength

and

ductility

characteristics

when

used

inelevated

temperature

applications.

Filler

metal

ER5554

was

developed

to

weld

base

metal

5454

and

both

alloyscontain

magnesium

contents

between

2.4%

and

3.0%.

Therefore,

both

alloys

are

suitable

for

elevated

temperatureapplications

and

are

not

susceptible

to

SCC.Filler

metal

ER4043does

not

have

magnesium

added

to

its

alloy

composition

and

can

be

used

to

weld

5xxx

series

alloys

with

up

to

2.5%

magnesium

(nominal)

aswell

as

other

base

metals

suitable

for

elevated

temperatureapplications

such

as

the

1xxx,

3xxx

and

6xxxbase

metals.10Filler

MetalSelecting

The

Correct

Filler

Metal

To

Match

AnodizedColorIf

post-weld

anodizingis

to

be

performed