Journal
METALLURGICAL AND MATERIALS TRANSACTIONS A-PHYSICAL METALLURGY AND MATERIALS SCIENCE
Volume 40A, Issue 11, Pages 2718-2728Publisher
SPRINGER
DOI: 10.1007/s11661-009-9964-4
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In the present work, mechanisms are proposed for solidification crack initiation and growth in aluminum alloy 6060 arc welds. Calculations for an interdendritic liquid pressure drop, made using the Rappaz-Drezet-Gremaud (RDG) model, demonstrate that cavitation as a liquid fracture mechanism is not likely to occur except at elevated levels of hydrogen content. Instead, a porosity-based crack initiation model has been developed based upon pore stability criteria, assuming that gas pores expand from pre-existing nuclei. Crack initiation is taken to occur when stable pores form within the coherent dendrite region, depending upon hydrogen content. Following initiation, crack growth is modeled using a mass balance approach, controlled by local strain rate conditions. The critical grain boundary liquid deformation rate needed for solidification crack growth has been determined for a weld made with a 16 pct 4043 filler addition, based upon the local strain rate measurement and a simplified strain rate partitioning model. Combined models show that hydrogen and strain rate control crack initiation and growth, respectively. A hypothetical hydrogen strain rate map is presented, defining conceptually the combined conditions needed for cracking and porosity.
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