Liquation Cracking Research Articles

Comparative Study on the Effect of External Magnetic Field on Aluminum Alloy 6061 and 7075 Resistance Spot-Welding Joints

This study investigates the effects of the external magnetic field on the microstructure and mechanical property aluminum alloy 6061-T6 and 7075-T651 resistance spot welding joints. The melting behavior of 6061 and 7075 was analyzed via the calculation of the phase diagram (CALPHAD) technique. The CALPHAD results indicate that, for the 6061 aluminum alloy, the liquid fraction shows a minimal increase at the beginning stage during the solid–liquid phase transition process but with a sharp rise at the ending stage (near the liquidus). In contrast, for the 7075 aluminum alloy, the liquid fraction gradually increases throughout the entire solid–liquid phase transition process. The differences in melting behavior between the 6061 and 7075 alloys lead to different liquation crack morphologies in their spot-welded joints. In the 6061 alloy, the cracks tend to be “eyebrow-shaped”, allowing the liquid metal in the nugget to feed the gaps, and this does not significantly compromise the mechanical properties of the joint. In contrast, the 7075 alloy develops slender cracks that extend through the partially melted zone (PMZ), making it difficult for the liquid metal to feed these gaps, thereby significantly deteriorating the joint’s mechanical strength. Compared to conventional resistance spot-welding joints, the heat exchange between the nugget and the workpiece is enhanced under the external magnetic field, leading to a wider PMZ. This exacerbates the detrimental effects of liquation cracks on the mechanical properties of the 7075 joints. Lap-shear tests indicate that the mechanical properties of the 6061 aluminum alloy joints are improved under electromagnetic stirring. For 7075 aluminum alloy joints, the mechanical properties improve when the welding current is below 34 kA. However, when the welding current exceeds 34 kA, because the widening of the PMZ increases the tendency for liquation cracks, the joint’s mechanical property is deteriorated.

Influence of travel speed on porosity and liquation cracking in cold wire pulsed gas metal arc welding of aa7075-t651 aluminum alloy

Influence of travel speed on porosity and liquation cracking in cold wire pulsed gas metal arc welding of aa7075-t651 aluminum alloy

Weldability of new Ni-based superalloy G27: Effect of pre-weld solution annealing on the hot cracking susceptibility

The hot cracking susceptibility of a new superalloy G27 was investigated by Varestraint weldability testing. The influence of pre-weld solution annealing conditions recommended by the alloy manufacturer to obtain different grain sizes (1010 °C/1 h, 1066 °C/0.5 h, and 1110 °C/1 h) for specific applications was studied. The fusion zone solidification cracking was independent of pre-weld solution annealing, and they are associated with the γ/Laves eutectic constituents. The solution-annealed material at 1010 °C/1 h showed the lowest extent of liquation cracking, while the 1110 °C/1 h condition was the most susceptible. The increased level of liquation cracking was primarily attributed to an increased grain size of pre-weld solution-annealed material. The heat-affected zone liquation cracking was identified to be caused by constitutional liquation of NbC and supersolidus melting.

Effect of aging treatment on the microstructure, cracking type and crystallographic texture of IN939 fabricated by powder bed fusion-laser beam

This study aimed to provide a comprehensive understanding of how aging treatments (namely, HT1 and HT2) affect the microstructure, cracking behavior, and crystallographic texture of IN939 fabricated by powder bed fusion-laser beam (PBF-LB) method. Although both aged samples demonstrated similar grain structure and recrystallization behavior according to the electron backscatter diffraction (EBSD) analysis, as well as the precipitation of bimodal γ′ phase and MC- and M23C6-type carbides, notable differences were observed in the size and morphology, particularly the γ′ phase. The HT1 sample displayed coarsened primary γ′ phase, with sizes reaching up to 2 μm and exhibiting varied morphologies, including irregular and cuboidal shapes. Additionally, this treatment led to the formation of some γ′-γ eutectic regions and plate-like η phase, along with the decomposition of MC-type carbides into M23C6-type carbides. In contrast, the HT2 sample displayed uniformly distributed spherical primary γ′ phase with sizes ranging from 70 to 120 nm, accompanied by very fine secondary γ′ phase. Furthermore, it was found that changes in both aged sample microstructures could result in the formation of strain-age cracks due to the γ′ phase formation and liquation cracks due to the partial remelting of lower melting point phases. The findings also revealed that with the application of aging treatments, the hardness of the as-fabricated sample (339.8 ± 3.4 HV) increased to 440.2 ± 5.6 HV and 508.1 ± 4.8 HV for the heat treatment of HT1 and HT2, respectively.

Effect of Nb content on microstructural evolution, mechanical and tribological properties of in situ alloyed copper-modified titanium produced using laser powder bed fusion

Control of the columnar to equiaxed transition (CET) is a major challenge in additively manufactured β titanium alloys. In this work, the promotion of CET was successfully achieved through in-situ fabrication of Ti-5Cu (wt.%) alloys with additions of 5, 15, and 25 wt.% Nb using elemental Ti, Cu, and Nb powders by employing laser powder bed fusion (LPBF). The alloy containing 5 wt.% Nb consisted of α lamellae, Ti2Cu precipitates, and unmelted β-Nb inclusions, whereas the 25 wt.% Nb alloy consisted of equiaxed β grains, ω precipitates, and Ti2Cu precipitates at the grain boundaries. In terms of mechanical properties, despite the presence of Nb inclusions and liquation cracks in the 5 wt.% Nb alloy, it showed a yield strength of 1051 ± 40 MPa and an elongation of 5.2% ± 1.3%. Both the strength and ductility decreased with increasing Nb content, e.g., the 25 wt.% Nb alloy exhibited a yield strength of 808 ± 53 MPa and an elongation of 1.6% ± 0.2%. As the Nb content increased from 5 to 25 wt.%, the Young's modulus decreased from 110 to 65 GPa. The 25 wt.% Nb alloy showed a high ratio of hardness to Young's modulus (H/E) and yield pressure (H3/E2). However, due to its brittle nature, the material manifested high wear rates. These findings provide a basis for the future development of novel low-modulus isotropic β-titanium alloys using LPBF.

Effect of welding current on the mechanical properties of Al 5083 alloy processed using high-current gas metal arc welding

This study investigated the effect of welding current during gas metal arc welding (GMAW) on the microstructure and composition of an Al 5083 alloy. As the welding current increased from 650 to 950 A, several changes were observed in the heat-affected zone (HAZ): grain coarsening and the formation of liquation cracks, and in the weld zone (WZ): increasing average secondary arm spacing and Mg loss. Therefore, the welding currents above 800 A are likely to cause liquation cracks in the HAZ and deterioration of the alloy's mechanical properties. Thus, welding condition with low heat input must be applied to improve the mechanical properties of the welds. This study provides a correlation between the weldability of Al 5083 alloy and welding current, offering a competitive advantage of liquid hydrogen storage containers.

Overcoming Liquation Cracking in AA7075 Welds via Friction Stir Processing Pre-weld Treatment: A Microstructural Approach

Overcoming Liquation Cracking in AA7075 Welds via Friction Stir Processing Pre-weld Treatment: A Microstructural Approach

Pre-softening HIP treatment enabled crack-healing and superior mechanical properties for René 142 superalloy fabricated via laser powder bed fusion

The generation of defects, such as cracks and pores, presents significant challenges for high-strength metals and alloys fabricated by the quick-emerging additive manufacturing technology, and subsequent post-processing treatments are often necessary before their practical applications. In this work, a novel heat treatment approach, involving a pre-softening treatment before hot isostatic pressing (HIP), is developed to facilitate the crack-healing in René 142 superalloy produced through laser powder bed fusion. Results demonstrate that René 142 alloy exhibits a propensity for severe cracking across a wide range of printing parameters, primarily in the form of solidification cracks and liquation cracks. These cracks are formed mainly due to a wide solidification range, the presence of a liquid film, and the concentration of residual stress. The pre-softening solution heat treatment significantly reduces dislocation density and residual stress levels, and the subsequent HIP together leads to a defect-free, dense structure for René 142 superalloy. Consequently, the René 142 alloy processed by the pre-softening HIP treatment achieves an excellent combination of yield strength (850 MPa), ultimate tensile strength (1227 MPa), and elongation (13.7 %), with pseudo-equiaxed grains (120–150 μm) and square γ′ precipitates (approximately 540 nm). These findings provide valuable insights for exploring crack elimination methods in other nickel-based superalloys fabricated through additive manufacturing.

Recent research progress in the mechanism and suppression of fusion welding-induced liquation cracking of nickel based superalloys

Recent research progress in the mechanism and suppression of fusion welding-induced liquation cracking of nickel based superalloys

Crack mitigation strategies for a high-strength Al alloy Al92Ti2Fe2Co2Ni2 fabricated by additive manufacturing

Laser powder bed fusion is capable of fabricating aluminum (Al) alloy parts with great geometrical flexibility and rapid prototyping for various industries. However, high strength Al alloys generally suffer from solidification cracks due to the steep thermal gradient associated with the laser fusion process. Here, we report several strategies to mitigate the hot crack susceptibility of a high strength Al92Ti2Fe2Co2Ni2 alloy. Routine processing parameter optimization based on varying laser power and scanning speed has to trade off porosity for producing crack-free parts, making it not suitable for load-bearing structural applications. Furthermore, secondary printing parameters, including laser strip length, laser defocus, scanning strategies, etc., improved printability but were insufficient to eliminate all the cracks. Crack morphology and residual stress measurements indicate that the cracks are generated in the solid state driven by large tensile residual stress, instead of solidification cracking or liquation cracking. Thus, an attempt was made to alleviate the residual stress in a controlled manner. By properly introducing a compliant, sacrificial, scaffold support structure to regulate crack propagation, near fully dense, crack-free parts could be successfully printed. The results were further verified by micro computed tomography, showing that cracking could be arrested in the support before propagating through the parts. This method can be readily applied to other alloy systems without modifying the chemistry.

Heat affected zone liquation cracking evaluation on FeMnAl alloys

ABSTRACT FeMnAl steels are currently generating a lot of interest with potential applications for structural parts in armored vehicles due to their lower density and outstanding mechanical properties. Despite the extensive mechanical performance and heat treatment exploration of this alloy class, further weldability investigation is required for future large-scale deployment. In the present study, the liquation cracking of four heats of cast FeMnAl alloys was investigated by the spot-Varestraint technique. The study focuses primarily on the effect of the major elements of the FeMnAl system: C, Mn and Al. Optical and electron microscopy were employed to investigate the microstructural features, and CALPHAD was employed to aid the discussion regarding the alloy’s composition differences and their effect on the liquation cracking susceptibility. The study was able to identify that compositions with the higher Mn, C, and lower Al presented the highest liquation cracking susceptibility. Conversely, composition presenting lower Mn, C, and Al showed the most resistant behavior. Furthermore, lower Al content promoted a fully-γ microstructure at low temperatures, which encouraged the appearance of longer cracks as a γ-matrix is more susceptible to HAZ cracking than a fully ferritic (α) or duplex (α + γ) microstructure.

Joining aluminum die castings and wrought aluminum by resistance spot welding

Resistance spot welding (RSW) is an economic, robust welding process, which is easy to automate and widely used in automotive industry. In this work, the resistance spot weldability of die-cast aluminum alloys EN AC-AlSi7MnMg, EN AC-AlSi9Mn and EN AC-AlSi10MnMg-T6/T7 to wrought aluminum alloy EN AW-AlSi1MnMg-T6 is investigated when applying the standard welding profile as recommended in VDA 238-401 considering main challenges in welding aluminum die castings, for example, porosity and inhomogenities. Weldability is best for EN AC-AlSi10MnMg-T6/T7, but the results show limited applicability of VDA 238-401 in general, especially for high total sheet thicknesses, because of invalid electrode force favouring spatter formation and weld spot irregularites. Still, all spot welds between die castings and 2 mm wrought aluminum sheets reach the recommended shear tension forces for spot diameter dw of 5·√t (2 mm: 5.95 kN; 3 mm: 8.96 kN; according to DIN EN ISO 18595), although being afflicted with solidification porosity and liquation cracking. Gas porosity is not observed and solidification porosity is only found to be significant for weld spot failure when being located close to the joining level, which is observed at welding depths of approximately 50% into the wrought aluminum sheet. Here, a failure path across the nugget is found. Weld porosity apart from the joining level is less significant and failure path is found along the fusion line between nugget and wrought aluminum. Instead, hardness difference between nugget and HAZ is the main reason for weld spot failure. Although the applied welding current profile is not suited best for RSW of mixed joints between aluminium die castings and wrought aluminium alloys, the results confirm its potential, for example, a significantly reduced gas porosity compared to applied fusion welding processes.

Solute segregation in a rapidly solidified Hastelloy-X Ni-based superalloy during laser powder bed fusion investigated by phase-field and computational thermal-fluid dynamics simulations

Solute segregation significantly affects material properties and is a critical issue in the laser powder-bed fusion (LPBF) additive manufacturing (AM) of Ni-based superalloys. To the best of our knowledge, this is the first study to demonstrate a computational thermal-fluid dynamics (CtFD) simulation coupled multi-phase-field (MPF) simulation with a multicomponent-composition model of Ni-based superalloy to predict solute segregation under solidification conditions in LPBF. The MPF simulation of the Hastelloy-X superalloy reproduced the experimentally observed submicron-sized cell structure. Significant solute segregations were formed within interdendritic regions during solidification at high cooling rates of up to 1.6 × 106 K s−1, a characteristic feature of LPBF. Solute segregation caused a decrease in the solidus temperature (TS), with a reduction of up to 38.4 K, which increases the risk of liquation cracks during LPBF. In addition, the segregation triggers the formation of carbide phases, which increases the susceptibility to ductility dip cracking. Conversely, we found that the decrease in TS is suppressed at the melt-pool boundary regions, where re-remelting occurs during the stacking of the layer above. Controlling the re-remelting behavior is deemed to be crucial for designing crack-free alloys. Thus, we demonstrated that solute segregation at the various interfacial regions of Ni-based multicomponent alloys can be predicted by the conventional MPF simulation. The design of crack-free Ni-based superalloys can be expedited by MPF simulations of a broad range of element combinations and their concentrations in multicomponent Ni-based superalloys.

Failure analysis of S30408 pipe cracking and preventive measures

BACKGROUND: The feed pipeline made from 30408 stainless steel of a new unit leaked during the air pressure test. OBJECTIVE: The present work aims to examine the specific cause of pipeline cracking, and providing effective approaches to avoid similar failures. METHODS: Macroscopic inspections of the cracked pipe defects were made on site immediately after leakage. Mechanical properties and hardness of specimens machined from the failed pipe were tested. In addition, microscopic analyses including material composition, microstructure observation and crack morphologies of the failed part were performed to get detail information. Composition of the feed raw material was also analyzed to identify whether it had been contaminated by corrosive elements or not. RESULTS: No impurity composition was found in the feed raw material. The element constituents, yield strength, tensile strength and hardness of the cracked pipe fulfill standard requirements. A number of scratches and defects with a size of several microns were found on the inner wall of the leaked pipe, and they were believed to be formed at the perforation step during pipeline processing. Liquation cracks were found at the pipeline butt weld joint, and they laid hidden dangers for the safety and steady operation of the pipeline. CONCLUSION: The overall analysis results indicated the pipeline leakage during air pressure test was caused by cracks initiated around inner wall defects, which sabotaged the bearing capacity of the pipe by wall thickness reduction and stress concentration. Therefore, improving the inner wall surface quality at the perforation step may help to avoid such failure. The metallurgical effect and weld stress caused during the welding process promoted the initiation and propagation of liquation cracks. The tendency of welding hot crack formation could be reduced by taking strict composition control of the welding rod and adopting reasonable welding parameters.

Investigation of HAZ Liquation Cracking Occurrence on Rail Steels

Investigation of HAZ Liquation Cracking Occurrence on Rail Steels

The role of the microstructural changes during induction preheating on the HAZ liquation cracking susceptibility of Ni-based superalloy

This work presents the influence of high-frequency induction preheating (900, 1000, 1100 °C) on liquation crack formation in the René 108 Ni-based superalloy. The investigation was divided into two parts: (1) characterization of the material's microstructure after preheating and (2) determining the influence of preheating on liquation cracking during autogenous gas tungsten arc welding. During preheating, the dissolution of γ′ precipitates showed accelerated progress with increase in temperatures. This dissolution involved the continuous thinning of each precipitate, as well as more intricate mechanisms, such as splitting. The mean size of the secondary γ′ decreased from 0.32 to 0.26 μm. In the heat-affected zone (HAZ) induced by welding, constitutional liquation of mainly γ' precipitates, with a contribution of M23C6 carbides and M5B3 borides, was observed. The formation of a thin non-equilibrium liquid film along high-angle grain boundaries led to the crack initiation and their further propagation during cooling. The eutectic γ–γ' re-solidification products were visible on the crack edges independently of preheat temperature. Preheating at 900 °C decreased the length and amount of liquation cracks, while preheating at 1100 °C allowed to prevent them due to the liquid-healing effect.

Short and Brief Review on Friction Stir Welding

Friction stir welding (FSW) has become the most popular welding technique for nonferrous alloys among researchers of the concerned field in the recent decade. It is a solid-state welding process and most suitable for nonferrous alloys, especially aluminium and magnesium alloys. Aluminium and magnesium alloys are the hot material for structural applications in transport vehicles, aerospace, and marine due to their lower densities and superior mechanical properties. Furthermore, FSW is associated with low temperature, which is responsible for eliminating defects of fusion welding such as porosity, liquation cracking, solidification, and cracking. This review article briefly introduces FSW and explains the different methods employed for FSW. Furthermore, process parameters, microstructural, mechanical properties, metallurgical investigations, advantages, disadvantages, applications, contemporary challenges and drawbacks, and future hotspots of FSW are identified.

Effect of local carbide formation behavior on repair weld liquation cracking susceptibility for long-term-serviced 247LC superalloy

This study assessed the liquation cracking temperature range (LCTR) for 247LC superalloy repair welds subjected to long-term and high-temperature exposure. To achieve this, the exposed specimens underwent simulations at 1273 K for 500, 1000, 3000, and 5000 h to replicate the long-term service conditions of gas turbines. Spot-Varestraint testing was employed to quantitatively measure LCTR variations. The metallurgical mechanism of the evaluated LCTR in the exposed 247LC superalloys was elucidated by analyzing the microstructural characteristics at the liquation cracking surface and performing thermodynamic calculations. The LCTR was evaluated to be 410 K for specimens exposed for 500 h, 440 K for 1000 h, 385 K for 3000 h, and 610 K for 5000 h. This indicates that the liquation cracking susceptibility of the repaired weld heat-affected zone significantly increased during the long-term service of the 247LC superalloy. After 5000 h of exposure, the formation of fine MC, M6C, and M23C6 carbides on the liquation cracking surface was characterized using transmission electron microscopy. The welding metallurgical mechanism underlying the severe liquation cracking susceptibility can be attributed to the fractions of MC (liquation initiation temperature: 1125–1356 K) and M6C (liquation initiation temperature: 1390–1420 K), which have lower liquation initiation temperatures than the solidus of the 247LC alloy (1530 K). Notably, the area fraction of MC and M6C increased during 5000 h of exposure, which led to an increase in LCTR from 410 K to 610 K.

Laser powder bed fusion of immiscible steel and bronze: A compositional gradient approach for optimum constituent combination

The microstructures and the mechanical properties of a laser powder bed fusion (LPBF) manufactured alloy coupons that were compositionally graded with austenitic stainless steel 316 L and bronze (Cu10Sn), which are immiscible, were investigated. While the microstructure of the pure 316 L contains only columnar γ-Fe grains, the formation of the equiaxed α-Cu, with α-Fe particles embedded in them, at the grain boundaries of the γ-Fe grains was observed upon alloying with Cu10Sn, for up to 50 wt.%. In the graded alloys with > 50 wt.% Cu10Sn, the microstructure inverts and contains α-Fe particle embedded α-Cu matrix along with some scattered γ-Fe grains. The two-dimensional phase-field simulations were employed to reproduced the phase transition and microstructure evolution in different compositions, revealing that the nucleation of γ-Fe occurs synchronously with the spinodal decomposition of liquid and that with further cooling, Cu-rich liquid solidifies and nanoscale spherical γ-Fe precipitates appear. Cross-sections with 10–40 wt.% Cu10Sn were found structurally unreliable owing to the formation of liquation cracks and shrinkage pores, whereas the rest of the build contained few pores and was crack-free. The Scheil solidification simulations together with the crack susceptibility index calculations over the entire compositions range of the CGA, reveal that when with < 50 wt.% Cu10Sn, liquid feeding to interdendritic regions of γ-Fe is limited, which is otherwise necessary to mitigate shrinkage-induced stresses. The hardness, yield and tensile strengths of the compositionally graded alloy in the cross-section with 50 wt.% Cu10Sn are higher than those of the parent constituents and the one with 80 wt.% Cu10Sn has the best combination of strength and ductility. The variations in strength and ductility are attributed to the microstructural and compositional changes in α-Cu matrix that were influenced by the formation of α-Fe particles. Finally, the appropriate proportions and the influence of the LPBF method in successfully mixing Cu10Sn and SS316L was discussed.

Microstructure characteristics and failure mechanisms of hybrid manufacturing of FGH96 and IC10 bimetal component using laser directed energy deposition

Hybrid manufacturing technology combines the cost advantage of traditional manufacturing with the flexibility benefit of additive manufacturing, thus providing an effective solution for creating gradient components. In this work, we deposit IC10 alloy powders on the FGH96 hot isostatic pressing substrates to prepare nickel-based gradient materials. A detailed analysis of the microstructural evolution in different regions is provided. The influence of thermal cycles on the heat-affected zone (HAZ) causes the γ′ phase to transform from a multimodal structure formed by hot isostatic pressing to a uniform spherical shape. The grain morphology changes from the ultrafine equiaxed grains of the substrate to fine equiaxed grains in the HAZ, then transforms into fine columnar grains in the gradient region, and finally changes to coarse columnar grains in the deposited zone. Moreover, the influence of grain orientation on the ability of epitaxial growth is investigated, and a grain orientation-dependent growth model is developed to predict the growth direction of columnar grains in the deposited layer. Such a non-uniform microstructure results in mechanical performance, including hardness and tensile strength, with distinctive heterogeneity along the building direction. The hybrid manufactured sample with higher yield strength than the pure alloys was primarily influenced by factors such as grain sizes, the sizes and distributions of the γ′ phases, as well as dislocation densities. However, due to the liquation crack in HAZ, the tensile elongation of the hybrid manufactured sample is lower than the pure alloy.