Unveiling Liquation and Segregation Induced Failure Mechanism in Thick Dissimilar Aluminum Alloy Electron-Beam Welds
This study presents new findings on the underlying failure mechanism of thick dissimilar electron-beam (EB) welds through a study on the AA 2219-AA 5083 pair. Contrary to the prior studies on EB welding of thin Al alloys, where liquation in the grain boundaries (GBs) in the partially melted zone (PM...
| Main Authors: | , , , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
MDPI AG
2022-03-01
|
| Series: | Metals |
| Subjects: | |
| Online Access: | https://www.mdpi.com/2075-4701/12/3/486 |
| _version_ | 1797444945823399936 |
|---|---|
| author | P. Mastanaiah G. Madhusudan Reddy Anirban Bhattacharya Angshuman Kapil Abhay Sharma |
| author_facet | P. Mastanaiah G. Madhusudan Reddy Anirban Bhattacharya Angshuman Kapil Abhay Sharma |
| author_sort | P. Mastanaiah |
| collection | DOAJ |
| description | This study presents new findings on the underlying failure mechanism of thick dissimilar electron-beam (EB) welds through a study on the AA 2219-AA 5083 pair. Contrary to the prior studies on EB welding of thin Al alloys, where liquation in the grain boundaries (GBs) in the partially melted zone (PMZ) was not observed, the present investigation for thick EB welds reports both liquation and increased segregation of Cu in the PMZ. The work is thus directed towards understanding the unusual observation in the PMZ of thick EB weld through investigation of the microstructural variation across the various regions of the produced weld. The microstructural results are correlated with the mechanical properties of the weld, i.e., hardness variation and tensile response. Results of this investigation suggest that unlike the convention that EB welding produces sound dissimilar Al welds, the weld performance for thick EB Al welds is affected by the heat input, the associated cooling rates, and most importantly by the base material thickness. Extensive liquation and Cu segregation induced failure in the PMZ on the AA 2219 side of the dissimilar weld. The underlying failure mechanism is explained through a heat-transfer analysis. Beyond a certain plate thickness, the heat transfer changes from two to three-dimensional. As a result, retarded cooling promotes liquation and Cu segregation in thick EB welds. |
| first_indexed | 2024-03-09T13:19:43Z |
| format | Article |
| id | doaj.art-b88e843e3d984b6883cbeb58ef2d9dcf |
| institution | Directory Open Access Journal |
| issn | 2075-4701 |
| language | English |
| last_indexed | 2024-03-09T13:19:43Z |
| publishDate | 2022-03-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Metals |
| spelling | doaj.art-b88e843e3d984b6883cbeb58ef2d9dcf2023-11-30T21:32:00ZengMDPI AGMetals2075-47012022-03-0112348610.3390/met12030486Unveiling Liquation and Segregation Induced Failure Mechanism in Thick Dissimilar Aluminum Alloy Electron-Beam WeldsP. Mastanaiah0G. Madhusudan Reddy1Anirban Bhattacharya2Angshuman Kapil3Abhay Sharma4Defence Research and Development Laboratory, Kanchanbagh, Hyderabad 500058, IndiaDefence Metallurgical Research Laboratory, Kanchanbagh, Hyderabad 500058, IndiaDepartment of Mechanical Engineering, Indian Institute of Technology Patna, Patna 801106, IndiaDepartment of Materials Engineering, Faculty of Engineering Technology, KU Leuven, Campus de Nayer, 2860 Sint-Katelijne Waver, BelgiumDepartment of Materials Engineering, Faculty of Engineering Technology, KU Leuven, Campus de Nayer, 2860 Sint-Katelijne Waver, BelgiumThis study presents new findings on the underlying failure mechanism of thick dissimilar electron-beam (EB) welds through a study on the AA 2219-AA 5083 pair. Contrary to the prior studies on EB welding of thin Al alloys, where liquation in the grain boundaries (GBs) in the partially melted zone (PMZ) was not observed, the present investigation for thick EB welds reports both liquation and increased segregation of Cu in the PMZ. The work is thus directed towards understanding the unusual observation in the PMZ of thick EB weld through investigation of the microstructural variation across the various regions of the produced weld. The microstructural results are correlated with the mechanical properties of the weld, i.e., hardness variation and tensile response. Results of this investigation suggest that unlike the convention that EB welding produces sound dissimilar Al welds, the weld performance for thick EB Al welds is affected by the heat input, the associated cooling rates, and most importantly by the base material thickness. Extensive liquation and Cu segregation induced failure in the PMZ on the AA 2219 side of the dissimilar weld. The underlying failure mechanism is explained through a heat-transfer analysis. Beyond a certain plate thickness, the heat transfer changes from two to three-dimensional. As a result, retarded cooling promotes liquation and Cu segregation in thick EB welds.https://www.mdpi.com/2075-4701/12/3/486electron-beam weldingpartially melted zonealuminum alloy 2219aluminum alloy 5083liquationsolute segregation |
| spellingShingle | P. Mastanaiah G. Madhusudan Reddy Anirban Bhattacharya Angshuman Kapil Abhay Sharma Unveiling Liquation and Segregation Induced Failure Mechanism in Thick Dissimilar Aluminum Alloy Electron-Beam Welds Metals electron-beam welding partially melted zone aluminum alloy 2219 aluminum alloy 5083 liquation solute segregation |
| title | Unveiling Liquation and Segregation Induced Failure Mechanism in Thick Dissimilar Aluminum Alloy Electron-Beam Welds |
| title_full | Unveiling Liquation and Segregation Induced Failure Mechanism in Thick Dissimilar Aluminum Alloy Electron-Beam Welds |
| title_fullStr | Unveiling Liquation and Segregation Induced Failure Mechanism in Thick Dissimilar Aluminum Alloy Electron-Beam Welds |
| title_full_unstemmed | Unveiling Liquation and Segregation Induced Failure Mechanism in Thick Dissimilar Aluminum Alloy Electron-Beam Welds |
| title_short | Unveiling Liquation and Segregation Induced Failure Mechanism in Thick Dissimilar Aluminum Alloy Electron-Beam Welds |
| title_sort | unveiling liquation and segregation induced failure mechanism in thick dissimilar aluminum alloy electron beam welds |
| topic | electron-beam welding partially melted zone aluminum alloy 2219 aluminum alloy 5083 liquation solute segregation |
| url | https://www.mdpi.com/2075-4701/12/3/486 |
| work_keys_str_mv | AT pmastanaiah unveilingliquationandsegregationinducedfailuremechanisminthickdissimilaraluminumalloyelectronbeamwelds AT gmadhusudanreddy unveilingliquationandsegregationinducedfailuremechanisminthickdissimilaraluminumalloyelectronbeamwelds AT anirbanbhattacharya unveilingliquationandsegregationinducedfailuremechanisminthickdissimilaraluminumalloyelectronbeamwelds AT angshumankapil unveilingliquationandsegregationinducedfailuremechanisminthickdissimilaraluminumalloyelectronbeamwelds AT abhaysharma unveilingliquationandsegregationinducedfailuremechanisminthickdissimilaraluminumalloyelectronbeamwelds |