Experimental investigation of the hot cracking mechanism in welds on the microscopic scale

doi:10.1007/s11706-011-0135-3

Front Mater Sci

2011, Vol. 5

Issue (2) : 135-145 https://doi.org/10.1007/s11706-011-0135-3

RESEARCH ARTICLE

Experimental investigation of the hot cracking mechanism in welds on the microscopic scale

V. PLOSHIKHIN^1,2(

), A. PRIHODOVSKY¹, A. ILIN¹

1. Neue Materialien Bayreuth GmbH, Bayreuth, Germany; 2. Integrative Simulation and Engineering of Materials and Processes (ISEMP), University of Bremen, 28359 Bremen, Germany

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Abstract

The results of the accurate experimental observations on binary Al-Si alloys are presented, which clearly demonstrate that the solidification cracking is a result of the accumulation of macroscopic tensile displacement in aβmicroscopic intergranular liquid film of segregates at the final stage of the weld metal solidification. The reconstructed mechanism of crack initiation provides a clear phenomenological interrelation between the cracking susceptibility, parameters of the welding process and properties of the base and filler material. The correspondent numerical model takes into account the effects of displacement accumulation as well as the influence of thermo-dynamical and thermo-mechanical properties of the welded material. It is successfully applied for development of technological means for elimination of the solidification cracking during welding of aluminium alloys AA6056, such as a multi-beam welding.

Keywords welding solidification cracking numerical simulation

Corresponding Author(s): PLOSHIKHIN V.,Email:Vasily.Ploshikhin@bccms.uni-bremen.de

Issue Date: 05 June 2011

Cite this article:

V. PLOSHIKHIN,A. PRIHODOVSKY,A. ILIN. Experimental investigation of the hot cracking mechanism in welds on the microscopic scale[J]. Front Mater Sci, 2011, 5(2): 135-145.

URL:

https://academic.hep.com.cn/foms/EN/10.1007/s11706-011-0135-3
https://academic.hep.com.cn/foms/EN/Y2011/V5/I2/135

Fig.1 Schematic illustration of the principal difference between the descriptions of the solidification cracking mechanism: Pellini [] considered the effect of the strain localisation which was not taken into account by Prokhorov [].

Fig.2 Experiments on determination of the critical thermo-mechanical conditions needed for the crack initiation: crack initiation by the welding close to the free edge; no crack initiation by the welding at a distance bigger than the critical one.

Fig.3 Initiation of the solidification crack (uncompleted crack) under lower and higher magnifications (top-view-sections, binary alloy Al-3%Si).

Fig.4 Initiation of the solidification crack (uncompleted crack) under lower and higher magnifications (cross-sections, binary alloy Al-3%Si).

Fig.5 Fictive solidification crack under lower and higher magnifications (top-view-sections, binary alloy Al-3%Si).

Fig.6 The experimental micrograph of the “frozen” tip of the centreline solidification crack (top view of the weld, binary Al-4%Si alloy); The solidification cracking mechanism reconstructed on the basis of experimental observations (schematic representation on the macro- and microscopic scale).

Fig.7 Phenomenological interrelation between parameters included in the cracking criterion and the process of the crack initiation.

Fig.8 Numerical simulation of the crack initiation and growth: the temperature fields at different steps of calculation.

Fig.9 Determination of the critical displacement and its use for the prediction of the solidification cracking in complex welded structures.

Fig.10 Experimental validation of the multi-beam technique: generation of the solidification crack due to the small distance to the free edge; suppression of the solidification crack under the same conditions due to the application of the additional laser beam.

Fig.11 Realisation of the multi-beam technique: preliminary numerical simulation of the temperature fields and the samples produced under the same conditions using the single-beam (above) and the double-beam (below) laser welding.

Fig.12 Dynamics of the strain accumulation: differences between the presented modeling approach and the classical Prokhorov’s model.

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