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Inter-relationship between residual stresses, microstructural evolutions, and mechanical responses of heat-treatable aluminum alloys during welding: a numerical and experimental study

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Abstract

Welding of heat-treatable aluminum alloys poses a significant challenge due to the formation of unwanted microstructural changes, inferior mechanical properties, and formation of residual stresses (RS). An understanding of the inter-relationship between these aspects is crucial for the successful design of sustainable welding structures. Given the complexity of these materials, a combination of numerical and experimental investigations is necessary to address this inter-relationship. In this work, the effect of welding heat input on the post-weld precipitation hardening, changes in mechanical properties, RS formation, and their inter-relationship in different welding regions of the heat-treatable AA2024 were numerically and experimentally studied. Two different thicknesses of the base material, 3.5 mm and 6 mm, were chosen to investigate the effect of different heat inputs and geometries. The results show that the highest RS are formed in the partially melted zone (PMZ) and heat-affected zone (HAZ), with values of 300 MPa and 221 MPa, respectively, for the 6-mm sample, where the mechanical properties and microstructure were most affected. These high-tensile RS accelerate the age hardening process of these regions, resulting in 20-HV changes in the PMZ and 14-HV changes in the HAZ in 70 days. The strength of the material due to these microstructural evolutions determined the load bearing of each region and their maximum RS.

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  1. Department of Materials Science and Engineering, Sharif University of Technology, Azadi Ave., Tehran, Iran

    Ardeshir Sarmast & Siamak Serajzadeh

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Sarmast, A., Serajzadeh, S. Inter-relationship between residual stresses, microstructural evolutions, and mechanical responses of heat-treatable aluminum alloys during welding: a numerical and experimental study. Int J Adv Manuf Technol 129, 4383–4398 (2023). https://doi.org/10.1007/s00170-023-12612-6

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