HW-4 Chap 6, 7, & 8
1. From the Al–Mg phase diagram, the equilibrium freezing range of 5052 aluminum (essentially Al–2.5Mg) is about
40°C. Suppose the welding speed is 4 mm/sand the diffusion coefficient DL is 3 x 10 -5 cm2 /s. Calculate the minimum
temperature gradient required for planar solidification at the weld centerline. What is the corresponding cooling rate?
Can this level of cooling rate be achieved in arc welding?
2. Let CE and CSM be respectively 35% and 15% Mg, and both the solidus and liquidus lines are essentially straight in
the Al–Mg system. T he melting point of pure Al is 660°C, and the eutectic temperature is 451°C. What is the
approximate volume fraction of the aluminum-rich dendrites in thefusion zone of autogenous 5052 aluminum weld?
3. It has been observed that aluminum alloys welded with the electron beam welding process show much finer
secondary dendrite arm spacing in the weld metal than those welded with GMAW. Explain why.
4. Which alloy has a greater tendency for planar solidification to break down, Al-0.01Cu or Al-6.3Cu and why?
5. How would preheating of the work-piece affect the secondary dendrite arm spacing in welds of aluminum alloys and
why?
6. In aluminum alloys such as 6061 and 5052, which often contain small amounts of Ti (say about 0.02wt%), the T i-rich
particles in the work-piece can be dissolvedwith a gas–tungsten arc by multi-passmelting. If the pre-weld is a multi-
pass weld intended to dissolve such particles and the grain structure is shown in Figure 1, what is the grain refining
mechanism in the test weld and why?
Figure 1
7. Equiaxed grains can often be foundin the crater of a weld that exhibits an essentially purely columnar grain structure,
as shown in Figure 2. Explain why.
Figure 2
8. Gutierrez and Lippold (23) made a preweld in aluminum alloy 2195 and then a test weld perpendicular to it, as shown
in Figure 3. (a) Do you expect to see a non-dendritic equiaxed zone near the fusion boundary of the test weld in the
overlap region and why or why not? (b) Same as (a) but with the work piece and the preweld solution heat treated
before making the test weld.
Figure 3
9. Part of a pure Ni ingot with large columnar grains is welded perpendicular to the grains, as shown in Figure 4. Sketch
the grain structure in the weld.
Figure 4
10. A pulsed arc weld is shown in Figure 5. Sketch the grain structure in the area produced by the last pulse.
Figure 5
11. It has been suggested that the secondary dendrite arm spacing d along the weld centerline can be related
quantitatively to the heat input per unit length of weld, Q/V. Based on the data of the dendrite arm spacing d as a
function of coolingrate e, similar to those shown in Figure 6.17a, it can be shown that݀ = ܽ߳ି ଵ/, where a and b are
constant with b being in the range of 2–3. (a) Express the dendrite arm spacing in terms of Q/V for bead-on-plate
welds in thick-section aluminum alloys. (b) How do the preheat temperature and thermal conductivity affect the
dendrite arm spacing? (c) Do you expect the relationship obtained to be very accurate?
12. T he size of the mushy zone is often an interesting piece of information for studying weld metal solidification.
Let݀ = ܽ߳ିଵ/, where d is the dendrite arm spacing and e the cooling rate. Consider how measurements of the
dendrite arm spacingacrossthe weld metalcan help determine the size of the mushy zone. Express the width of the
mushy zone in the welding direction x, as shown in Figure 6, in terms of the dendrite arm spacing d, the welding
speed V, and the freezing temperature range T (= T L - T E).
13. It has been observed that the greater the heat inputper unit length of weld (Q/V), the longer it takes to homogenize
the micro-segregation in the weld metal of aluminum alloys for improvingits mechanicalproperties. Let ݀ = ܽ߳ିଵ/,
where d is the dendrite arm spacingand e the cooling rate. Expressthe time required for homogenization (t) in terms
of Q/V.
14. An Al–1% Cu alloy is welded autogenously by GTAW, and an Al–5% Cu alloy is welded under identical condition.
Which alloy is expected to develop more constitutional super-cooling and why? Which alloy is likely to have more
equiaxed dendrites in the weld metal and why?
15. An Al–5% Cu alloy is welded autogenously by GTAW and by EBW under the same welding speed but different heat
inputs (much less in the case of EBW). Which weld is expected to experience more constitutional supercooling and
why? Which weld is likely to have more equiaxed dendrites and why?
16. In autogenous GT AW of aluminum alloys, how do you expect the amount of equiaxed grains in the weld metal to be
affected by preheating and why?
17. In autogenous GT AW of aluminum alloys, how do you expect the dendrite arm spacing of the weld metal to be
affected by preheating and why?
18. Figure 7 is a micrograph near the fusion line of an autogenous gas–tungsten arc weld in a Fe–49% Ni alloy sheet
(19). Explain the solidification microstructure, which is to the right of the fusion line (dark vertical line).
Figure 6
Figure 7
