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ML00118 - Jan.2018donated by: Davi Pegado

Non qualified GMAW of Aluminum Plates

Macrography of the horizontal position joint. It was welded in three passes, and one additional pass from the root. Root pass - 153A, 20V, 156mm/s (wire speed), 3.5 mm/s (welding speed), 933 J/mm. Second pass - 162A, 20V, 156mm/s (wire speed), 5.8 mm/s (welding speed), 592 J/mm. Third pass - 155A, 19V, 156mm/s (wire speed), 5.9 mm/s (welding speed), 523 J/mm. Additional at the root - 161A, 23V, 187mm/s (wire speed), 8.5mm/s (welding speed), 467J/mm.

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of the horizontal position joint. It was welded in three passes, and one additional pass from the root. Root pass - 153A, 20V, 156mm/s ( speed), 3.5 mm/s ( speed), 933 J/mm. Second pass - 162A, 20V, 156mm/s ( speed), 5.8 mm/s ( speed), 592 J/mm. Third pass - 155A, 19V, 156mm/s ( speed), 5.9 mm/s ( speed), 523 J/mm. Additional at the root - 161A, 23V, 187mm/s ( speed), 8.5mm/s ( speed), 467J/mm.
M

Material

Aluminum Magnesium Manganese
  • ALLOY 5083
  • AWS A 5.10 ER 5183
Ds

Description

coupons were welded by conventional process, in all positions, to test a according to . The WPS was not qualified because the mechanical test results indicated low ultimate strength for the and that opened during tests. The metallurgical analysis evidenced hot cracks in the root due to imposed high welding energy. The use of a ceramic backing favored the adoption of unsuitable welding parameters and too opened joint design.

C

Chemistry (% in weight)

Plate base metal

0.07Si; 0.18Fe; 0.05Cu; 0.44Mn; 4.21Mg; 0.07Cr; 0.07Zn; 0.05Ti.

Weld metal

0.08Si; 0.14Fe; 0.02Cu; 0.61Mn; 4.44Mg; 0.07Cr; 0.02Zn; 0.06Ti.

Associated Images
Micrography of the welded joint, at the root, presenting hot cracks. The imposed high energy in the root due to the ceramic backing support created a condition for cracking.
1100
VIEW
ML00118 / Jan.2018
Non qualified GMAW of Aluminum Plates
M - Aluminum Magnesium ManganeseP - Welded Testpiece for QualificationAp - ShipCd - Non qualified
Cm - Keller Etched Micrography by OMDf - Hot cracking
Micrography of the welded joint, at the root, showing hot cracks with intergranular morphology.
146
VIEW
ML00118 / Jan.2018
Non qualified GMAW of Aluminum Plates
M - Aluminum Magnesium ManganeseP - Welded Testpiece for QualificationAp - ShipCd - Non qualified
Cm - Keller Etched Micrography by OMDf - Hot cracking
Micrographic detail of the welded joint, at the root, presenting hot cracks. The presence of these defects were responsible for reducing the material strenght (rupturing in lower strenght than the requirements) and ductility (cracking in bending tests).
116
VIEW
ML00118 / Jan.2018
Non qualified GMAW of Aluminum Plates
M - Aluminum Magnesium ManganeseP - Welded Testpiece for QualificationAp - ShipCd - Non qualified
Cm - Keller Etched Micrography by OMDf - Hot cracking
The welded joint of the flat position is shown from the root side. It is possible to see that the use of the backing generated the possibility for melting the base metal out of the groove, without detection of this condition during welding, responsible for creating defects and avoiding the WPS qualification.
102
VIEW
ML00118 / Jan.2018
Non qualified GMAW of Aluminum Plates
M - Aluminum Magnesium ManganeseP - Welded Testpiece for QualificationAp - ShipCd - Non qualified
Cm - Aspect Before AnalysisDf - General View
The welded joint of the vertical up position is shown from the root side. It is possible to see that the use of the backing generated the possibility for melting the base metal out of the groove, without detection of this condition during welding, responsible for creating defects and avoiding the WPS qualification.
122
VIEW
ML00118 / Jan.2018
Non qualified GMAW of Aluminum Plates
M - Aluminum Magnesium ManganeseP - Welded Testpiece for QualificationAp - ShipCd - Non qualified
Cm - Aspect Before AnalysisDf - General View
Summary of the welding conditions and qualification test results. NON QUALIFIED WPS. The individual parameters for each welding position are presented in the legend of each macrography, that also presents the amount of beads.
117
VIEW
ML00118 / Jan.2018
Non qualified GMAW of Aluminum Plates
M - Aluminum Magnesium ManganeseP - Welded Testpiece for QualificationAp - ShipCd - Non qualified
Cm - WPS summaryDf - Welded Joint
Low magnification micrography of the plate base metal, presenting granular structure not clearly identified and aligned particles.
88
VIEW
ML00118 / Jan.2018
Non qualified GMAW of Aluminum Plates
M - Aluminum Magnesium ManganeseP - Welded Testpiece for QualificationAp - ShipCd - Non qualified
Cm - Keller Etched Micrography by OMDf - Base Metal
Micrography of the plate base metal, presenting granular structure evidenced by the different shadows in the grains.
76
VIEW
ML00118 / Jan.2018
Non qualified GMAW of Aluminum Plates
M - Aluminum Magnesium ManganeseP - Welded Testpiece for QualificationAp - ShipCd - Non qualified
Cm - Keller Etched Micrography by OMDf - Base Metal
Micrographic detail of the aligned particles in the plate base metal. The grain boundaries are not clearly identified in this higher magnification.
73
VIEW
ML00118 / Jan.2018
Non qualified GMAW of Aluminum Plates
M - Aluminum Magnesium ManganeseP - Welded Testpiece for QualificationAp - ShipCd - Non qualified
Cm - Keller Etched Micrography by OMDf - Base Metal
Low magnification micrography of the welded joint at the heat affected zone of the flat position, in the last bead (face). Longitudinal section of the plate, transverse to the welded joint.
68
VIEW
ML00118 / Jan.2018
Non qualified GMAW of Aluminum Plates
M - Aluminum Magnesium ManganeseP - Welded Testpiece for QualificationAp - ShipCd - Non qualified
Cm - Keller Etched Micrography by OMDf - Last Bead HAZ
Micrography of the welded joint at the heat affected zone of the flat position, in the last bead (face). Longitudinal section of the plate, transverse to the welded joint.
64
VIEW
ML00118 / Jan.2018
Non qualified GMAW of Aluminum Plates
M - Aluminum Magnesium ManganeseP - Welded Testpiece for QualificationAp - ShipCd - Non qualified
Cm - Keller Etched Micrography by OMDf - Last Bead HAZ
Micrographic detail of the welded joint at the heat affected zone of the flat position, in the last bead (face). Longitudinal section of the plate, transverse to the welded joint.
57
VIEW
ML00118 / Jan.2018
Non qualified GMAW of Aluminum Plates
M - Aluminum Magnesium ManganeseP - Welded Testpiece for QualificationAp - ShipCd - Non qualified
Cm - Keller Etched Micrography by OMDf - Last Bead HAZ
Low magnification micrography of the welded joint at the heat affected zone of the flat position, in the root. Longitudinal section of the plate, transverse to the welded joint.
53
VIEW
ML00118 / Jan.2018
Non qualified GMAW of Aluminum Plates
M - Aluminum Magnesium ManganeseP - Welded Testpiece for QualificationAp - ShipCd - Non qualified
Cm - Keller Etched Micrography by OMDf - Root HAZ
Micrography of the welded joint at the heat affected zone of the flat position, in the root. Longitudinal section of the plate, transverse to the welded joint.
50
VIEW
ML00118 / Jan.2018
Non qualified GMAW of Aluminum Plates
M - Aluminum Magnesium ManganeseP - Welded Testpiece for QualificationAp - ShipCd - Non qualified
Cm - Keller Etched Micrography by OMDf - Root HAZ
Micrographic detail of the welded joint at the heat affected zone of the flat position, in the root. Longitudinal section of the plate, transverse to the welded joint.
46
VIEW
ML00118 / Jan.2018
Non qualified GMAW of Aluminum Plates
M - Aluminum Magnesium ManganeseP - Welded Testpiece for QualificationAp - ShipCd - Non qualified
Cm - Keller Etched Micrography by OMDf - Root HAZ
Macrography of the flat position welded joint. It was welded in three passes, with the following parameters. Root pass - 157A, 21V, 146mm/s (wire speed), 3.2 mm/s (welding speed), 1090 J/mm. Second pass - 161A, 21V, 146mm/s (wire speed), 4.2 mm/s (welding speed), 833 J/mm. Third pass - 155A, 21V, 146mm/s (wire speed), 5.1 mm/s (welding speed), 664 J/mm.
48
VIEW
ML00118 / Jan.2018
Non qualified GMAW of Aluminum Plates
M - Aluminum Magnesium ManganeseP - Welded Testpiece for QualificationAp - ShipCd - Non qualified
Cm - Keller Etched MacroDf - Flat Position
Macrographic detail of the flat position welded joint, showing the three passes. The large extension of the heat affected zone in the root reveals the too high imposed energy, melting out of the root gap. The shining spots are pores.
42
VIEW
ML00118 / Jan.2018
Non qualified GMAW of Aluminum Plates
M - Aluminum Magnesium ManganeseP - Welded Testpiece for QualificationAp - ShipCd - Non qualified
Cm - Keller Etched MacroDf - Flat Position
Macrography of the horizontal position joint. It was welded in three passes, and one additional pass from the root. Root pass - 153A, 20V, 156mm/s (wire speed), 3.5 mm/s (welding speed), 933 J/mm. Second pass - 162A, 20V, 156mm/s (wire speed), 5.8 mm/s (welding speed), 592 J/mm. Third pass - 155A, 19V, 156mm/s (wire speed), 5.9 mm/s (welding speed), 523 J/mm. Additional at the root - 161A, 23V, 187mm/s (wire speed), 8.5mm/s (welding speed), 467J/mm.
47
VIEW
ML00118 / Jan.2018
Non qualified GMAW of Aluminum Plates
M - Aluminum Magnesium ManganeseP - Welded Testpiece for QualificationAp - ShipCd - Non qualified
Cm - Keller Etched MacroDf - Horizontal Position
Macrographic detail of the horizontal position welded joint, showing the three passes welded from one side and the fourth pass welded after removing the ceramic backing. Big pores and liquation were identified.
40
VIEW
ML00118 / Jan.2018
Non qualified GMAW of Aluminum Plates
M - Aluminum Magnesium ManganeseP - Welded Testpiece for QualificationAp - ShipCd - Non qualified
Cm - Keller Etched MacroDf - Horizontal Position
Macrography of the vertical up position welded joint. It was welded in three passes, with the following parameters. Root pass - 115A, 21V, 162mm/s (wire speed), 2.6 mm/s (welding speed), 1090 J/mm. Second pass - 143A, 21V, 162mm/s (wire speed), 5.5 mm/s (welding speed), 594 J/mm. Third pass - 144A, 21V, 162mm/s (wire speed), 6.1 mm/s (welding speed), 979 J/mm.
39
VIEW
ML00118 / Jan.2018
Non qualified GMAW of Aluminum Plates
M - Aluminum Magnesium ManganeseP - Welded Testpiece for QualificationAp - ShipCd - Non qualified
Cm - Keller Etched MacroDf - Vertical Up Position
Macrographic detail of the vertical up position welded joint, showing the three passes. The second and third passes penetrated to much, almost through wall thickness. The shining spots are pores, some of a large size.
41
VIEW
ML00118 / Jan.2018
Non qualified GMAW of Aluminum Plates
M - Aluminum Magnesium ManganeseP - Welded Testpiece for QualificationAp - ShipCd - Non qualified
Cm - Keller Etched MacroDf - Vertical Up Position
Macrography of the flat position welded joint. It was welded in three passes, with the following parameters. Root pass - 159A, 21V, 147mm/s (wire speed), 3.5 mm/s (welding speed), 979 J/mm. Second pass - 170A, 22V, 168mm/s (wire speed), 7.7 mm/s (welding speed), 538 J/mm. Third pass - 172A, 23V, 168mm/s (wire speed), 7.0 mm/s (welding speed), 587 J/mm.
43
VIEW
ML00118 / Jan.2018
Non qualified GMAW of Aluminum Plates
M - Aluminum Magnesium ManganeseP - Welded Testpiece for QualificationAp - ShipCd - Non qualified
Cm - Kalling Etched MacroDf - Overhead Position
Macrographic detail of the overhead position welded joint, showing the three passes. The shining spots are pores, some of a large size.
42
VIEW
ML00118 / Jan.2018
Non qualified GMAW of Aluminum Plates
M - Aluminum Magnesium ManganeseP - Welded Testpiece for QualificationAp - ShipCd - Non qualified
Cm - Keller Etched MacroDf - Overhead Position
Tensile testpieces after testing. The rupture of the testpieces occurred at the margin of the weld.
39
VIEW
ML00118 / Jan.2018
Non qualified GMAW of Aluminum Plates
M - Aluminum Magnesium ManganeseP - Welded Testpiece for QualificationAp - ShipCd - Non qualified
Cm - Testpiece aspectDf - Flat Position
Tensile testpieces after testing. The rupture of the testpieces occurred at the margin of the weld.
35
VIEW
ML00118 / Jan.2018
Non qualified GMAW of Aluminum Plates
M - Aluminum Magnesium ManganeseP - Welded Testpiece for QualificationAp - ShipCd - Non qualified
Cm - Testpiece aspectDf - Horizontal Position
Tensile testpieces after testing. The rupture of the testpieces occurred at the margin of the weld.
36
VIEW
ML00118 / Jan.2018
Non qualified GMAW of Aluminum Plates
M - Aluminum Magnesium ManganeseP - Welded Testpiece for QualificationAp - ShipCd - Non qualified
Cm - Testpiece aspectDf - Vertical Up Position
Tensile testpieces after testing. The rupture of the testpieces occurred at the margin of the weld.
39
VIEW
ML00118 / Jan.2018
Non qualified GMAW of Aluminum Plates
M - Aluminum Magnesium ManganeseP - Welded Testpiece for QualificationAp - ShipCd - Non qualified
Cm - Testpiece aspectDf - Overhead Position
Broken bending testpiece of the 3G position. The presence of cracks at the root caused the lack of material ductility and opening of cracks during bending. The procedure was not qualified.
46
VIEW
ML00118 / Jan.2018
Non qualified GMAW of Aluminum Plates
M - Aluminum Magnesium ManganeseP - Welded Testpiece for QualificationAp - ShipCd - Non qualified
Cm - Testpiece aspectDf - Cracks