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ML00070 - Jan.2019donated by: Noah Nahas

Automotive Light Alloy Wheel Repaired By Welding

Profile of the rim of the wheel, total width 215 mm. See the schematic drawing in the next figure.

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Profile of the rim of the wheel, total width 215 mm. See the schematic drawing in the next figure.
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Material

Aluminum Silicon Magnesium
  • NF EN 1706 EN AC AlSi7Mg0,3
  • UNS A03560
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Description

The wheel was damaged because the car travelled in a bumpy road. The cast rim was repaired by and machining and the wheel was in service for a short time. The adopted for the process is similar to the and the is refined compared to the cast base metal, presenting higher strength, although defects formed during repair (hot and ) were observed in this wheel that was .

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Chemistry (% in weight)

Rim Analysis

92Al; 7.25Si; 0.32Mg; 0.05Fe; 0.10Ti; 0.01Zn.

Associated Images
Aspect of the wheel. See the schematic drawing in the next figure
467
VIEW
ML00070 / Jan.2019
Automotive Light Alloy Wheel Repaired By Welding
M - Aluminum Silicon MagnesiumP - RimAp - AutomotiveCd - Removed From Service
Cm - Aspect Before AnalysisDf - General View
Schematic drawing presenting the position in the rim where the repair by welding was conducted. The region was machined after the welding.
77
VIEW
ML00070 / Jan.2019
Automotive Light Alloy Wheel Repaired By Welding
M - Aluminum Silicon MagnesiumP - RimAp - AutomotiveCd - Removed From Service
Cm - Identification drawingDf - Weld Repair
Profile of the rim of the wheel, total width 215 mm. See the schematic drawing in the next figure.
64
VIEW
ML00070 / Jan.2019
Automotive Light Alloy Wheel Repaired By Welding
M - Aluminum Silicon MagnesiumP - RimAp - AutomotiveCd - Removed From Service
Cm - Transverse Section AspectDf - Transverse Section
Schematic drawing indicating the location of the repair by welding
60
VIEW
ML00070 / Jan.2019
Automotive Light Alloy Wheel Repaired By Welding
M - Aluminum Silicon MagnesiumP - RimAp - AutomotiveCd - Removed From Service
Cm - Identification drawingDf - Transverse Section
Detail of the welded region in the rim of the light alloy wheel.
126
VIEW
ML00070 / Jan.2019
Automotive Light Alloy Wheel Repaired By Welding
M - Aluminum Silicon MagnesiumP - RimAp - AutomotiveCd - Removed From Service
Cm - Aspect Before AnalysisDf - At the Surface
Aspect of the welded region after dye check showing several indications, later identified as hot cracks associated to the repair welding.
114
VIEW
ML00070 / Jan.2019
Automotive Light Alloy Wheel Repaired By Welding
M - Aluminum Silicon MagnesiumP - RimAp - AutomotiveCd - Removed From Service
Cm - Aspect by NDTDf - Cracks
Micrography of the cast rim, base metal, in the as polished condition, showing the dendrites of alpha aluminum and interdendritic eutectic Si/alpha, silicon particles in a coalesced condition that sugegsts a solution annealed treatment.
119
VIEW
ML00070 / Jan.2019
Automotive Light Alloy Wheel Repaired By Welding
M - Aluminum Silicon MagnesiumP - RimAp - AutomotiveCd - Removed From Service
Cm - Micrography by OMDf - Base Metal
Micrography of the cast rim, base metal, showing the dendrites of alpha aluminum and interdendritic eutectic Si/alpha, silicon particles in a coalesced condition that suggests a solution annealed treatment. After etching it is possible to identify a transgranular precipitation (aging) and a dark FeSiAl phase (neddles).
87
VIEW
ML00070 / Jan.2019
Automotive Light Alloy Wheel Repaired By Welding
M - Aluminum Silicon MagnesiumP - RimAp - AutomotiveCd - Removed From Service
Cm - Keller Etched Micrography by OMDf - Base Metal
Micrographic detail of the cast rim, base metal, in the as polished condition, showing the dendrites of alpha aluminum and interdendritic eutectic Si/alpha, silicon particles in a coalesced condition that sugegsts a solution annealed treatment.
74
VIEW
ML00070 / Jan.2019
Automotive Light Alloy Wheel Repaired By Welding
M - Aluminum Silicon MagnesiumP - RimAp - AutomotiveCd - Removed From Service
Cm - Micrography by OMDf - Base Metal
Micrographic detail of the cast rim, base metal, showing the dendrites of alpha aluminum and interdendritic eutectic Si/alpha, silicon particles in a coalesced condition that suggests a solution annealed treatment. After etching it is possible to identify a transgranular precipitation (aging) and a dark FeSiAl phase (neddles).
62
VIEW
ML00070 / Jan.2019
Automotive Light Alloy Wheel Repaired By Welding
M - Aluminum Silicon MagnesiumP - RimAp - AutomotiveCd - Removed From Service
Cm - Keller Etched Micrography by OMDf - Base Metal
Low magnification micrography of the welded region, showing the base metal in the bottom, the fusion zone (between the liquidus and solidus temperatures) in the center and the weld metal in the top. There are pores close to the weld metal and in the fusion zone the interdendritic space was melted and the eutectic morphology was changed.
64
VIEW
ML00070 / Jan.2019
Automotive Light Alloy Wheel Repaired By Welding
M - Aluminum Silicon MagnesiumP - RimAp - AutomotiveCd - Removed From Service
Cm - Keller Etched Micrography by OMDf - Weld Repair
Low magnification micrography of the welded region, showing the interface between the base in the bottom and the fusion zone (between the liquidus and solidus temperatures), as well as the weld metal in the top. There are pores close to the weld metal and in the fusion zone the interdendritic space was melted and the eutectic morphology was changed. Keller etch.
50
VIEW
ML00070 / Jan.2019
Automotive Light Alloy Wheel Repaired By Welding
M - Aluminum Silicon MagnesiumP - RimAp - AutomotiveCd - Removed From Service
Cm - Micrography by SEMDf - Weld Repair
The cast material that presents for the base metal a coalesced silicon particles in the interdendritic space and intragranular precipitation shows a solution effect at the heat affected zone.
52
VIEW
ML00070 / Jan.2019
Automotive Light Alloy Wheel Repaired By Welding
M - Aluminum Silicon MagnesiumP - RimAp - AutomotiveCd - Removed From Service
Cm - Keller Etched Micrography by OMDf - Heat Affected Zone
Micrographic detail of the cast rim at the heat affected zone presenting coalesced Si particles at the interdendritic space an neddles of Fe rich phase. Keller etch.
47
VIEW
ML00070 / Jan.2019
Automotive Light Alloy Wheel Repaired By Welding
M - Aluminum Silicon MagnesiumP - RimAp - AutomotiveCd - Removed From Service
Cm - Micrography by SEMDf - Heat Affected Zone
The coalesced silicon particles in the interdendritic space of the base metal presents a remelting at the fusion zone.
44
VIEW
ML00070 / Jan.2019
Automotive Light Alloy Wheel Repaired By Welding
M - Aluminum Silicon MagnesiumP - RimAp - AutomotiveCd - Removed From Service
Cm - Keller Etched Micrography by OMDf - Fusion Line
The coalesced silicon particles in the interdendritic space of the base metal presents a remelting at the fusion zone. The micrography by SEM shows the exactly line where the eutectic is remelted and refined. Keller etch.
40
VIEW
ML00070 / Jan.2019
Automotive Light Alloy Wheel Repaired By Welding
M - Aluminum Silicon MagnesiumP - RimAp - AutomotiveCd - Removed From Service
Cm - Micrography by SEMDf - Fusion Line
The weld metal presents the same structure than the base metal (alpha aluminum dendrites with Si/Al alpha eutectic in the interdendritic space) but refined when compared to the base metal. Also the hardness level is higher for the weld metal than the base metal.
37
VIEW
ML00070 / Jan.2019
Automotive Light Alloy Wheel Repaired By Welding
M - Aluminum Silicon MagnesiumP - RimAp - AutomotiveCd - Removed From Service
Cm - Keller Etched Micrography by OMDf - Weld Metal
Refined dendrites in the weld metal. The Si/Al alpha eutectic in the interdendritic space is also refined. Keller etch.
38
VIEW
ML00070 / Jan.2019
Automotive Light Alloy Wheel Repaired By Welding
M - Aluminum Silicon MagnesiumP - RimAp - AutomotiveCd - Removed From Service
Cm - Micrography by SEMDf - Weld Metal
Hot cracks in the fusion zone. The eutectic regions were melted and cracked in an interdendritic morphology.
37
VIEW
ML00070 / Jan.2019
Automotive Light Alloy Wheel Repaired By Welding
M - Aluminum Silicon MagnesiumP - RimAp - AutomotiveCd - Removed From Service
Cm - Micrography by SEMDf - Cracks
Detail of the hot cracks in the fusion zone. The eutectic regions were melted and cracked in an interdendritic morphology. Keller etch.
50
VIEW
ML00070 / Jan.2019
Automotive Light Alloy Wheel Repaired By Welding
M - Aluminum Silicon MagnesiumP - RimAp - AutomotiveCd - Removed From Service
Cm - Micrography by SEMDf - Cracks