Strain localization at longitudinal weld seams during plastic deformation of Al–Mg–Si–Mn–Cr extrusions: The role of microstructure

Abstract

The current work was motivated by the increasing use of hollow aluminum extruded profiles for automotive applications and the need for a better understanding of the mechanical response of extrusion seam welds. Two Al–Mg–Si alloys were studied, one without Mn and one with 0.5 wt%Mn and 0.15 wt%Cr. A high temperature homogenization was applied, resulting in a high density of α-Al(Fe,Mn)Si dispersoids in the Mn containing alloy, and an essentially dispersoid free microstructure in the other. The alloys were extruded through a simple porthole die (with two ports) to produce a strip with a centerline weld seam. The Mn free extrudate had a recrystallized grain structure whereas the Mn and Cr containing material was unrecrystallised. There were significant spatial variations of microstructure between the weld seam and surrounding regions, in particular the crystallographic texture. Tensile tests were conducted with the loading direction perpendicular to the weld seam using digital image correlation (DIC) to characterize the local strain distribution. Strain localization and final fracture occurred at weld seam for the unrecrystallized material whereas these occurred away from the weld line in the recrystallized case. The role of local crystallographic texture was examined through polycrystal plasticity simulations using the visco-plastic self consistent code (VPSC). These simulations indicated that the weld seam region was mechanically stronger than the surrounding region for the recrystallized alloy and correspondingly weaker for the unrecrystallized case, thereby rationalizing the experimental results of strain localization and final fracture location.