Study of the effect of porosity formation on weld joints of AA6061-T6 aluminium alloy using two different filler metals

Syed Roslee Sayd Bakar, Mohd Faizol Ahmad Ibrahim, Azman Jalar @ Jalil, Norinsan Kamil Othman, Syarif Junaidi Sjarifuddin Djalil, Mohd Yazid Ahmad

Research output: Contribution to journalArticle

Abstract

The effect of porosity on weld metal of AA6061-T6 aluminium alloy with 6 mm thick plates using two dissimilar filler metals (ER4043 and ER5356) in the gas metal arc welding (GMAW) process is investigated. This paper provides a characterisation of porosity in terms of distribution and location of pores in the weldment region. Porosity characterisation was conducted using an optical microscope coupled with image analyser. The existing pores in the weldment using ER4043 (Al-Si 5%) was compared with the weldment using ER5356 (Al-Mg 5%). From this investigation, it is shown that the pores were distributed and localised mainly at the edges and root of the weldment with ER5356. However, for the weldment with ER4043, the pores were scattered mainly in the centre region. This is due to the effect of convections in the molten metal, solidification rate and gases induced during the welding process. In addition, the results of the tensile test indicated that the welding had affected the strength and ductility of the two fillers selected. The weldment with ER5356 showed a drop of 50% in ultimate tensile strength (UTS) and 40 % in elongation; while the weldment with ER 4043 showed a drop of 70% in UTS and 90% in elongation. The different principle alloying elements of these two filler metals played a significant role in the distribution of porosity in the AA6061-T6 weldments, and had influenced the tensile strength and ductility of the weld joints.

Original languageEnglish
Pages (from-to)11-18
Number of pages8
JournalDefence S and T Technical Bulletin
Volume4
Issue number1
Publication statusPublished - 2011

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Filler metals
Aluminum alloys
Welds
Porosity
Tensile strength
Ductility
Elongation
Welding
Gas metal arc welding
Alloying elements
Liquid metals
Solidification
Fillers
Microscopes
Metals
Gases

Keywords

  • AA 6061-T6
  • Arc weld
  • Filler metal
  • Porosity
  • Tensile strength

ASJC Scopus subject areas

  • Engineering(all)

Cite this

Study of the effect of porosity formation on weld joints of AA6061-T6 aluminium alloy using two different filler metals. / Bakar, Syed Roslee Sayd; Ibrahim, Mohd Faizol Ahmad; Jalar @ Jalil, Azman; Othman, Norinsan Kamil; Djalil, Syarif Junaidi Sjarifuddin; Ahmad, Mohd Yazid.

In: Defence S and T Technical Bulletin, Vol. 4, No. 1, 2011, p. 11-18.

Research output: Contribution to journalArticle

Bakar, Syed Roslee Sayd ; Ibrahim, Mohd Faizol Ahmad ; Jalar @ Jalil, Azman ; Othman, Norinsan Kamil ; Djalil, Syarif Junaidi Sjarifuddin ; Ahmad, Mohd Yazid. / Study of the effect of porosity formation on weld joints of AA6061-T6 aluminium alloy using two different filler metals. In: Defence S and T Technical Bulletin. 2011 ; Vol. 4, No. 1. pp. 11-18.
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