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Static and Dynamic Mechanical Properties of Longitudinal Weld Seams

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Static and Dynamic Mechanical Properties of Longitudinal Weld Seams in Industrial AA6060, AA6082 and AA7020 Aluminum Extrusions

Andrew J. den Bakker, Nedal Aluminium B.V., Utrecht, The Netherlands
Simon-Peter Edwards1, Netherlands Institute for Metals Research, Delft, The Netherlands
Ludmila ‘t Hoen-Velterop, and Rens Ubels, National Aerospace Laboratory NLR, Marknesse, The Netherlands

Track: EXTRUSION/DIE, PRACTICAL - Hollow Profiles and Heat Exchanger Profiles

ABSTRACT --- Owing to the tooling setup, complex hollow extrusions contain
weld seams where the aluminum streams rejoin in the die. For structural
applications, the mechanical performance of these weld seams is required to be
comparable to the longitudinal bulk material properties. The properties of these
weld seams are governed by process-related phenomena and the tooling
geometry. For different alloys this combination of die shape and process settings
needs to be optimized to ensure good performance of the weld seams, especially
regarding dynamic mechanical performance (especially fatigue performance).
The objective of this investigation was to determine the weld seam properties of
industrially relevant alloys. Full-scale extrusion test runs were conducted, in
which box-section profiles were produced of a type where weld seam quality of
AA6082 and AA7020 parts was known to be a critical factor. AA6060 was
included in these experiments as a reference material. Samples from the
extrusions were obtained from various positions and orientations, and
subsequently subjected to extensive mechanical characterization by means of
tensile, fracture toughness, and fatigue testing. Results are correlated with the
processing data, and through microstructural characterization, the particular
failure mode of the material was investigated. It is concluded that the effect of
sample orientation and the influence of the weld seams on the mechanical
properties is significantly different for the investigated alloys.

© Extrusion Technology for Aluminum Profiles Foundation (ET Foundation). All rights reserved. No part of The Proceedings may be reproduced in any form without the express written permission of the ET Foundation.