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Exacerbated stress corrosion cracking in arc welds of 7xxx aluminum alloys

Henry Granjon prize 2017 winner Category B: Materials Behaviour and Weldability

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Abstract

Cu-lean, high-strength 7xxx series aluminum alloys (AAs) are increasingly utilized in welded structures for vehicle light-weighting. The complex stress corrosion cracking (SCC) phenomenon in the 7xxx AA base metals has been extensively studied in the literature. However, the SCC in a welded joint is further compounded by the existence of highly inhomogeneous microstructure formed during welding. The present investigation is focused on the exacerbated SCC observed in the joints made of AA 7003-T4 (Al–Zn–Mg) plates welded with AA 5356 (Al–Mg) filler metal. It studies the contribution to SCC by a variety of factors especially the precipitates in the weld toe and the heat-affected zone in the as-welded and post-weld heat-treated conditions. The stress intensity factor experienced at the crack tip is ranked using the peak strain measured using the digital image correlation technique. Based on the testing results, a theory for the exacerbated SCC in the weld joints is established. Finally, the feasibility of two different engineering solutions to SCC in these weldments is discussed.

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Abbreviations

AA:

Aluminum alloy

AW:

As-welded

BM:

Base metal

DIC:

Digital image correlation

EDM:

Electron discharge machining

EDS:

Energy-dispersive x-ray spectroscopy

FM:

Filler metal

FOZ:

Fused-overlap zone

FL:

Fusion line

FSW:

Friction stir welding

FZ:

Fusion zone

HAZ:

Heat-affected zone

IGC:

Intergranular corrosion

KI :

Stress intensity

KISCC :

Critical SCC stress intensity

PB:

Paint bake

PBTC:

Paint bake thermal cycle

SCC:

Stress corrosion cracking

SCC:

Stress corrosion cracking

TMAZ:

Thermo-mechanically affected zone

WT:

Weld toe

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Acknowledgements

The present research was supported by Honda R&D Americas, Inc. through the Manufacturing and Materials Joining Innovation Center (Ma2JIC), a NSF industry/university cooperative research center (I/UCRC). STEM was performed by Rachel Seibert of the Illinois Institute of Technology using the FEI Talos F200X STEM provided by the Department of Energy, Office of Nuclear Energy, Fuel Cycle R&D Program and the Nuclear Science User Facilities. Helpful discussion with Dr. Niyanth Sridharan of Oak Ridge National Laboratory (ORNL) is acknowledged.

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Authors and Affiliations

  1. Department of Materials Science and Engineering, The Ohio State University, Columbus, OH, 43210, USA

    T. E. Borchers & W. Zhang

  2. Honda R&D Americas, Inc., Raymond, OH, USA

    A. Seid & P. Shafer

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  1. T. E. Borchers
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  2. A. Seid
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Correspondence to T. E. Borchers.

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Recommended for publication by Commission IX - Behaviour of Metals Subjected to Welding

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Borchers, T.E., Seid, A., Shafer, P. et al. Exacerbated stress corrosion cracking in arc welds of 7xxx aluminum alloys. Weld World 62, 783–792 (2018). https://doi.org/10.1007/s40194-018-0564-z

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