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Metallurgical and Mechanical Properties of Heat Treatable Aluminum Alloy

AA6082 Welds

Article in International Journal of Applied Engineering Research · January 2017

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 International Journal of Applied Engineering Research ISSN 0973-4562 Volume 12, Number 11 (2017) pp. 2832-2839
© Research India Publications. http://www.ripublication.com

Metallurgical and Mechanical Properties of Heat Treatable Aluminum

Alloy AA6082 Welds

M. El-Shennawy 1a*, Kh. Abdel-Aziz 1b and A. A. Omar 1c

1
Taif University, Engineering College, Mechanical Engineering Department, Taif, Post Code 888, KSA.
a
On leave from Helwan University, faculty of Engineering, Mechanical Engineering Department, Helwan, Egypt.
b
On leave from Zagazig University, Faculty of Engineering, Materials Engineering Department, Zagazig, Egypt.
c
On leave from Benha University, Faculty of Engineering, Mechanical Engineering Department, Benha, Egypt.
*
Corresponding Author, e-mail: [email protected]

aORCID: 0000-0002-2870-0418

Abstract Copper, magnesium, zinc, manganese, lithium and silicon are

commonly added to aluminum as alloying elements.
Heat treatable alloy AA6082 is a medium strength alloy with
Chromium, zirconium, titanium, lead, nickel and bismuth are
have excellent formability from simple to complex profiles by
also added as small additions. Aluminum alloys are either
extrusion and good corrosion resistance characteristics. It is
wrought or cast alloys. For wrought alloys, the designation
one of the most widely used alloys and has considerable
contains 4 digits while in cast alloys fifth digit is added. Table
industrial interest. These materials can be heat treated to
1 shows the designation system for wrought alloys.
produce precipitation to various degrees. Mg and Si are the
major solutes they increase the strength of the alloy by
precipitation hardening. This article presents a survey for the
Strength and Corrosion Resistance of Aluminum
main work done concerning welding and heat treatment
carried out to this alloy. Metallurgical and mechanical Unalloyed aluminum has low strength. When adding alloying
properties of the AA6082 similar and dissimilar welds were elements such as copper, silicon, manganese and magnesium
reviewed. the strength property increases to tailor particular applications.
At cold environment, tensile strength of aluminum increases
Keywords: Al-Mg-Si alloy, AA 6082, TIG, MIG, heat-
while retaining its toughness. This is an advantage over steel
treatable alloy, heat treatment, metallurgical properties,
which loses its toughness to be brittle at low temperature.
mechanical properties, similar welding, dissimilar welding.
Tensile strength of pure/unalloyed aluminum is around 90
INTRODUCTION
MPa and can be increased to over 700 MPa for some heat-
Aluminum and its alloys are extensively utilized in many treatable alloys. Main methods to increase the aluminum
industries such as automotive, shipbuilding, aircraft, structural strength are alloying, heat treatment and cold working. These
applications, appliances, food packaging and transportation methods are applied to pure aluminum to achieve the
industry [1-7] due to their high strength to weight ratio and application requirements.
corrosion resistance and for their attractive mechanical
properties achieved by thermal treatments.
Heat Treatment of Aluminum
Table 1. Wrought aluminum alloy designation
There are various heat treatments which can be carried out for
Alloying Element Wrought aluminum to increase its metallurgical and mechanical
Non (99%+ Aluminum) 1XXX properties. These treatment methods can be briefly described
Copper 2XXX as: Homogenization, Annealing, Precipitation/Age Hardening
and Solution Heat Treatment. In the designation system a
Manganese 3XXX
suffix will appear describing the heat treatment method.
Silicon 4XXX Namely; “F” for fabricated, “O” for annealed wrought
Magnesium 5XXX products, “T” for heat treated, “W” for solution heat treatment
and “H” for non-heat treatable alloys (3XXX, 4XXX &
Magnesium + Silicon 6XXX
5XXX) which can be cold worked or strain hardened.
Zinc 7XXX
Lithium 8XXX

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HEAT TREATABLE ALUMINUM ALLOY 6082 and rate of strengthening increases until the overall Mg and Si
ratio in the alloy is close to approximately 0.4. Dispersoid
Aluminum–magnesium–silicon (Al–Mg–Si) denoted as
formation and recrystallization behavior in Al-Mg-Si-Mn had
6XXX series alloys are medium strength heat treatable alloys
been studied and showed that the cold deformation influences
and have excellent formability from simple to complex
the recrystallization and grain growth [18].
profiles by extrusion [8] and good corrosion resistance
characteristics [5]. Mg and Si are the major solutes they
increase the strength of the alloy by precipitation hardening.
There has been a considerable industrial interest in these
alloys because two-thirds of all extruded products are made of
aluminum and 90% of those are made from 6XXX series
alloys [9]. In this series, AA6082 is one of the most widely
used alloys [10]. These materials can be heat treated to
produce precipitation to various degrees.

Table 2. Chemical composition of aluminum alloy 6082

Si Fe Cu Mn Mg Cr Zn Ti Other elements
Each Total
Fig. 1 (a) Tensile curves of post-ECAP aged specimens at
100C for 6 and 30 h (b) ruptured tensile specimen after
0.7-1.3 0.5 0.10 0.4-1.0 0.6-1.2 0.25 0.20 0.1 0.05 0.15
ECAP, and (c) ruptured tensile specimen after ECAP-aging
[19].
Chemical and mechanical properties of aluminum alloy 6082
is summarize in Table 2 and Table 3, respectively [11-13].

Table 3. Mechanical properties of aluminum alloy 6082

Hardness Vickers
Hardness Brinell
Tensile Strength

Fatigue Endur.
Shear Strength
0.20% (MPa)

Limit (MPa)
Proof Stress

Elongation

Elongation
A50 (%)
Temper

A5 (%)
(MPa)

(MPa)

HV
HB

O 60 130 85 27 26 35 35 120
T1 170 260 155 24 24 70 75 200
T4 170 260 170 19 19 70 75 200
T5 275 325 195 11 11 90 95 210
T6 310 340 210 11 11 95 100 210

Fig. 2 Tensile properties of the 6069 and 6061 alloys after

The T6 treatment involving solution heat treatment and dynamic ageing and static peak-ageing at 170C [20].
subsequent artificial aging and quenching is a common
method to increase the strength of the alloy [14, 15]. The
solution heat treatment is first performed at 500°C to obtain Aluminum alloy 6082 could be strengthen by combining
the supersaturated  solid solution. Artificial aging is obtained aging treatment and ECAP process [19]. An increase in both
by heating to about 200°C for various amounts of time and strength and ductility of the ECAPed specimen was achieved
leads to precipitation of various phases (leading to the stable  via appropriate post-aging treatment as shown in Fig. 1. A
phase). The hardness and strength are determined by the comparison between static and dynamic aging using equal
precipitate type, density and size [16]. channel angular extrusion (ECAE) of two Al-Mg-Si alloys
[20] showed dynamic aging is efficient in executing aging
Precipitation hardening in Al-Mg-Si alloys with and without treatment that results in superior mechanical properties of this
excess Si had been investigated [17]. Excess Si increases the alloy Al-Mg-Si as shown in Fig. 2.
effective amount of the hardening phases above ~ 0.9 wt.% Si

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(b) MIG welding

Figure 3. Data from ageing alloy 6082 from as-quenched Figure 4. Schematic representation for (a) TIG and (b) MIG
condition compared with the model for both high and low welding processes.
temperature regimes [22].

Age hardening of heat treatable aluminum alloys including

6082 was discussed and modelled [21]. The model is used to
describe the change in yield strength due to age hardening.
The model was applied to a number of heat treatments,
establishing a basis for such problems as the prediction of the
strength loss in the heat-affected zone of welds [22]. The data
for aging alloy 6082 from as-quenched condition reduced to
equivalent isothermal treatments, and compared with the
model for both high and low temperature regimes is shown in
Fig. 3 [22].

Figure 5. Friction stir welding (FSW) process.

WELDING OF ALUMINUM ALLOY 6082
Aluminum and its weldable alloys are usually welded using
fusion and non-fusion welding processes. Tungsten Inert-Gas Friction stir welding (FSW) process is used nowadays for
(TIG) and Metal Inert-Gas (MIG) welding processes are welding metals in general especially aluminum alloys because
preferred for aluminum welding because of their high quality of its simple and excellent weld quality it produces. The
welds. Figure 4 shows schematic representation for both TIG process is non-fusion welding process. The problems of fusion
and MIG welding processes. welding are eliminated with this process. Principals of FSW
process is shown in Fig. 5.

Metallurgical Characteristics of Welded AA6082

Fusion welding of aluminum alloy 6082 is widely applied in
many applications but weldability problems do exist, namely,
solidification cracking, liquation cracking, porosity and
overaging of the heat affected zone (HAZ) [23-33]. The
relatively high thermal expansion of Al-alloys is believed to
be the main cause for the susceptibility of these alloys to weld
cracking. Their large changes in volume upon freezing as well
as their wide solidification temperature range [25-27]. This
phenomenon dramatically decreases the mechanical properties
of the welded joint. The same effect is observed due to the
(a). TIG welding creation of a soft zone in the HAZ caused by overaging as a

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result of the thermal cycle imposed on the joint during

welding [27]. The mechanical properties of the joint for the
latter case can be recovered by postweld heat treating
(solutionizing, quenching and aging) [34, 35]. Rapid
quenching, however, can lead to distortion of the welded joint
and, inconveniently, in many cases it might not be accessible
for heat treating and it has to go on service in the as welded
condition [36]. The microstructural changes that lead to loss
of hardening and thereby mechanical strength in the HAZ of
heat treatable aluminum alloys is a well-recognized issue that
has to be taken into account when designing welded structural
components [37].
(a)
The strength falls below the allowable limit specified by the
standard. This is likely to be the result of the larger thermal
affection due to the multi-passes procedure needed to fill the
V groove butt joint. Although at high cost, this procedure can
be suppressed by using the high concentration energy welding
processes such as laser or electron beam [38-42].
Solidification crack sensitivity for aluminum alloy 6082-T6
was measured using Houldcroft test. TIG welding was
applied. The weldability test showed high values of 44%. The
selection of proper filler metal is important to lower this
value. This investigation concluded that alloying with high
amount of Mg (5%) can positively influence solidification
cracking very much [43]. Crack susceptibility ratio for the
6082 alloy is shown in Fig. 6.

(b)
Figure 7. Microstructure of welded AA6082 by TIG welding
at (a) 100A and (b) 140A [44].

Effect of welding parameters of laser arc hybrid welding on

weld quality of AA 6082, was studied and concluded that
increasing arc current or laser power, or decreasing welding
speed reduces weld percent porosity [45].
Figure 6. Cracking susceptibility ratio for TIG welded AA
6082, filler metal influence [43].
Mechanical Properties of Welded AA6082
Microstructure and hardness of welded aluminum alloy 6082 Non-fusion welding, specifically FSW for 6082-T6 exhibited
were investigated under various current of TIG welding [44]. a variation in mechanical properties of the joint with changing
Using current of 140 ampere resulted in fine grain structure of process parameters [46]. Tensile strength of FSW welds
and uniform dimples. This enhanced tensile strength of the was directly proportional to travel (welding) speed. Studying
joint. Hardness increased with decreased current. Figure 7 the variation of hardness through the weld zone, HAZ and
shows a comparison between microstructure of welded AA TMAZ showed minimum values at the TMAZ of AA 6082. In
6082 at 100A and 140A using TIG welding process [44]. the same time the fracture in tensile specimens coincided with
the line of lowest hardness for AA 6082 [47].

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where fracture toughness values calculated from Charpy V

test (Eq. 1 [57]) exhibited its minimum values [55].
𝐾𝐼𝐶 2 𝐶𝑉𝑁
( ) = 0.64 ( − 0.01) (1)
𝜎𝑌𝑆 𝜎𝑌𝑆

Especial interest had been forwarded to AA 6082-T6 when

process modelling applied to this alloy weldments [58, 59].
Empirical formula (Eqs. 2, 3 [58, 59]) had been established to
calculate yield strength and ultimate tensile strength using
Vickers hardness test values (1 kg load).
𝑅𝑝0.2 (𝑀𝑃𝑎) = 3.0 𝐻𝑉 − 48.1 (2)

𝑅𝑚 (𝑀𝑃𝑎) = 2.6 𝐻𝑉 − 39.8 (3)

Toughness measured experimentally using CTOD test for

Figure 8. Local true stress versus local hardness [48]. welded AA 6082 showed better results compared to base
metal while tensile results were poorer [60]. Postweld
artificial aging for welded joints of AA 6082 markedly
Linear stress-hardness relationship was established, relating reduced the toughness. Full postweld heat treatment improved
the hardness in different AA 6082-T6 weld zones with local strength to base metal level, but toughness remained low [60].
tensile properties. The welds were performed by friction stir Postweld heat treatment (PWHT) and shot peening effect on
welding (FSW) [48]. Relationship is shown in Fig. 8. fatigue strength for MIG welded AA 6082 was discussed on
For Al-Mg-Si alloys the operating conditions for the T-joint the basis of variations in the microstructure (morphology and
continuous welding by continuous wave (CW) Nd:YAG laser grain structure) of the weld metal [61]. After PWHT fatigue
for producing the maximum ultimate tensile load in the joints resistance increased with 26%, yield strength with 40% and
were investigated [49]. Filler wire feed rate and welding speed ultimate tensile strength with 6% compared to as welded. Shot
were the factors with strong influence on the tensile load of peening of the welded joints increased the fatigue resistance
the assembly. Mechanical and metallurgical properties of with 38% [61].
extrusion welds of AA 6082-T4 showed less ductility in weld Fatigue behavior had been discussed for FSWed AA 6082-T6
regions and precipitates of Mg2Si is the cause for premature [62, 63]. Due to compressive residual stress field at the crack
failure at these locations [50]. vicinity, lower crack propagation rate was verified for the
Using TIG welding process to weld AA 6082 has an effect on welded material in comparison with the HAZ or the base
mechanical properties of the welded joint. Shielding gas flow material [62]. Welding defects such as shear lips and tunnel
rate, welding current and filler material are among the main _in particular_ formed in the retracting side of FSWed joint
factors affecting tensile strength of the welded joint [51]. lead significantly to reduction of the fatigue lives of AA6082.
Thermo-mechanical analysis in TIG welding of AA 6082 Stress concentration created near shear lips have less effect on
proved its feasibility in measuring welding residual stresses fatigue life than tunnel defect [63].
[52]. Mechanical and metallurgical characteristics of Standard test method followed in testing the base material of
dissimilar welded joints are the main problem to be solved wrought or cast aluminum alloy products can be found at
using proper welding parameters. Welding AA 6082 with AA ASTM B557 – 84 [64]. To test welded joints, AWS B4.0 –
5083 using pulsed current TIG welding showed better joint 2007 is applied [65].
strength and hardness when using filler wire 5356 [53].
MIG welding process is spread in industrial applications. It is
used successfully for similar welding of AA 6082 [54, 55] and CONCLUSIONS
dissimilar welding of AA5083 with AA 6082 [56]. The main concluding remarks those could be drawn from this
Mechanical properties including tensile strength, Vickers revision are:
hardness, Charpy impact strength and fatigue strength were
measured for welded AA 6082 [55]. The residual strength of  Aluminum alloy 6082 is most widely used in the
the welded joint recorded 60% of the parent metal. Reduction industrial applications including structures and
in tensile strength and hardness values were existed in HAZ. aerospace.
Fatigue test specimens, on the contrary fractured in WM  AA6082 can be welded successfully by fusion welding

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