Fatigue and fracture toughness of electron beam welded joints of aluminum alloy 6156 (Al–Mg–Si) for aerospace applications

Alexopoulos, Nikolaos D.; Examilioti, Theano N.; Stergiou, Vasileios; Kourkoulis, Stavros K.

doi:10.1111/ffe.13516

Cited by 6 publications

(6 citation statements)

References 42 publications

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“…Microhardness increases from the HAZ region towards the BM. It is suggested that a solution annealing treatment should be performed to restore the hardness [36].…”

Section: Microhardness Testmentioning

confidence: 99%

Numerical and experimental study for electron beam welding process of Al6061-T6 material

Küçüktürk

Atkaya

2022

Mater. Res. Express

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Joining the aluminium 6061-T6 alloy (Al6061-T6) using Electron Beam Welding (EBW) wais important, especially in aerospace. Although the EBW method has been used for different materials in the literature, there are a limited number of studies for Al6061-T6 alloy. The study aimed at the weldability and welding quality of 6061-T6 aluminium alloy plates by experimentally and numerically using the EBW technique. A numerical model has been generated to obtain the appropriate voltage, beam current, and welding speed parameters to simulate the EBW process instead of the hit and trial method, which is costly. The numerical model is based on a user-defined function based on the heat source as a function of temperature, welding parameters and material properties. The validation of the model has been compared by obtained width from numerical model and experimental work. Three EBW parameter sets were employed with the numerical model. Three different experimental parameter sets were determined according to the most suitable processing parameter that emerged from the numerical model, and experimental studies were carried out. Experimental studies showed defects in the microstructure due to process defects by unsuitable parameters. While the mechanical strength was 70% of the tensile strength performance compared to the main material, the elongation performance was 75%. The microhardness of the heat affected zone was measured as 84% of the base material, and a hardness reduction of 40% was also observed in the fusion zone. In addition, it showed that using the proper parameter set can eliminate such defects. The application of post-weld heat treatment procedures that can effectively improve the mechanical properties could be investigated in future studies.

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“…Microhardness increases from the HAZ region towards the BM. It is suggested that a solution annealing treatment should be performed to restore the hardness [36].…”

Section: Microhardness Testmentioning

confidence: 99%

Numerical and experimental study for electron beam welding process of Al6061-T6 material

Küçüktürk

Atkaya

2022

Mater. Res. Express

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“…It can be applied to weld titanium alloys, aluminum alloys, heat-resistant steel and Ni-based alloys, etc. [1][2][3][4][5] Ni-based superalloys, a class of materials having high temperature resistance and oxidation resistance, are widely used in aero engines, gas turbines, and other high-temperature components. 6,7 GH4169 is a grade of Ni-based superalloy from China, and its maximum operating temperature is 650 C, which has the similar microstructure and mechanical properties to Inconel 718.…”

Section: Introductionmentioning

confidence: 99%

“…Electron beam welding (EBW) has been used for the manufacture and maintenance of aero engines for decades due to the excellent performance in dimensional accuracy and welding quality. It can be applied to weld titanium alloys, aluminum alloys, heat‐resistant steel and Ni‐based alloys, etc 1–5 . Ni‐based superalloys, a class of materials having high temperature resistance and oxidation resistance, are widely used in aero engines, gas turbines, and other high‐temperature components 6,7 .…”

Section: Introductionmentioning

confidence: 99%

Effect of texture evolution and defect on the crack initiation of a Ni‐based superalloy electron beam welded joint

Wen,

Liu,

Jiang

et al. 2023

Fatigue Fract Eng Mat Struct

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Electron beam welding (EBW), a high‐quality and precise joining process, is widely used in aerospace manufacturing. In this study, through in situ scanning electron microscope (SEM) fatigue experiments and X‐ray computed tomography (CT) scanning technology, we revealed the fatigue crack initiation and propagation mechanism in GH4169 superalloy EBW joints under different post‐welding heat treatment conditions. The welded pores have a decisive effect on the fatigue properties of direct aging treatment welded joints. Fatigue cracks initiate from pore defects on the surface or in the subsurface. Due to the heterogeneous microstructure in weld seam, fatigue cracks tend to grow along the primary dendrite axis and secondary dendrite arms. Besides, in homogenization and aging treatment specimen, intergranular fatigue cracks tend to nucleate in the slip zone of large grains and twin boundaries. Although homogenization treatment can eliminate segregation, it also results in significant grain growth in both weld seam and base material.

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“…Low weight and high strength are the main basis for the selection of materials for high‐speed trains. Additionally, 6XXX series Al alloys have been widely used in structural body parts because of their low density, medium strength, good‐forming ability, and excellent welding performance 1–5 . However, fatigue cracks usually occur in the Al alloy components because of the alternating load during long‐term service 6–12 .…”

Section: Introductionmentioning

confidence: 99%

“…Additionally, 6XXX series Al alloys have been widely used in structural body parts because of their low density, medium strength, good-forming ability, and excellent welding performance. [1][2][3][4][5] However, fatigue cracks usually occur in the Al alloy components because of the alternating load during long-term service. [6][7][8][9][10][11][12] It is estimated that 80% to 90% of the engineering component failures may result from a fatigue fracture.…”

Section: Introductionmentioning

confidence: 99%

Effects of aging state on fatigue properties of 6A01 aluminum alloy

Gong

Zhang

Duan

et al. 2022

Fatigue Fract Eng Mat Struct

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The high‐cycle fatigue (HCF) experiments were carried out for different aging states to study the effects of the aging state and yield strength on the fatigue properties of a 6A01 Al alloy. The results show that the 6A01 Al alloy with the highest yield strength at a peak‐aging (PA) state can exhibit the highest fatigue strength in comparison with the overaged (OA) state and the underaged (UA) state. The main reason is that the increased strength of the 6A01 Al alloy at the PA state can improve the plastic deformation resistance and inhibit the fatigue crack initiation. Additionally, the UA has a similar yield strength but a higher fatigue strength compared with the OA, which shows that the aging state also has a significant influence on the fatigue properties. Finally, combined with the previous studies on the 2XXX and 7XXX Al alloys, the effects of the aging state and yield strength on the fatigue properties of Al alloys are summarized.

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Fatigue and fracture toughness of electron beam welded joints of aluminum alloy 6156 (Al–Mg–Si) for aerospace applications

Cited by 6 publications

References 42 publications

Numerical and experimental study for electron beam welding process of Al6061-T6 material

Numerical and experimental study for electron beam welding process of Al6061-T6 material

Effect of texture evolution and defect on the crack initiation of a Ni‐based superalloy electron beam welded joint

Effects of aging state on fatigue properties of 6A01 aluminum alloy

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