ALUMINUM Q&A

Q: I am about to start welding procedure specification development in preparation for manufacturing a welded aluminum structure. I have only developed welding procedures to the requirements of the American Welding Society (AWS) D1.1, Structural Welding Code Steel, with which I am very familiar. Can you please provide me with any information on the differences I will need to consider when working with the AWS D1.2, Structural Welding Code Aluminum? Any information about areas that may cause me problems during welding procedure development would be greatly appreciated. A: You have asked a very good question.
While the process of welding procedure development for aluminum is in many ways the same as that for steel, there are some very significant differences between the requirements of the two codes. Also, there are some details associated with the qualification testing of aluminum that most certainly can cause problems if not fully understood.

BY TONY ANDERSON

Fig. 1 The mechanism for the wraparound bend test fixture, the preferred method for bend testing aluminum weldments.

Range of Material Thickness

One fundamental difference between these two codes, which is not normally a

problem, but which I will mention anyway, is that the AWS D1.1 steel code has a specific limitation on thickness for which it is intended to be used. Steel less than 18 in. in thickness is not intended to be used with this code but rather with the AWS D1.3, Structural Welding Code Sheet Steel. The AWS D1.2 aluminum code has no such restriction.

Prequalification of Welding Procedure Specifications

The AWS D1.1 steel code has, for many years, made use of prequalified welding procedures. The code provides the applicable requirements, which if conformed to, will allow the user to produce documented welding procedure specifications without the formal process of producing welding procedure qualification records and associated mechanical testing. The AWS D1.2 aluminum code, on the other hand, does not have the provision for the prequalification of welding procedure specifications. All procedures developed with the AWS D1.2 aluminum code must be tested to be qualified in accordance with the code requirements. (Discussion within the AWS D1G Subcommittee on Aluminum Structures would suggest that prequalified welding procedure specifications may be something we see in the future.)

Guided Bend Testing

There are some significant differences between the procedures used within these codes for guided bend testing. The particular differences that I would like to point
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out are those related to the special bending conditions that are required when qualifying procedures in accordance with the AWS D1.2 aluminum code. Because of the physical characteristics of some aluminum alloys, there are some very specific differences between how some alloys are bend tested. The M23 base alloys (6xxx series) may be bend tested under either of two conditions, as-welded or annealed. In the as-welded condition, if the test sample is over 18 in. (3 mm), its thickness shall be reduced to 18 in. (3 mm) thickness before bending and then bent over a diameter of 2116 in. (52 mm). Specimens of less than 18 in. (3 mm) thickness shall be bent over a diameter of 1612 thickness. Annealed specimens of M23 material of 38 in. (10 mm) thickness shall be bent over a 623 thickness diameter. The annealing practice that is conducted to the sample before bending is as follows: Hold for 2 to 3 h at 775F (410C) then cool at 50F/h (28C/h) to 500F (260C). The rate of cooling below 500F (260C) is unimportant. Welds made with M24 (2xxx series) material shall be annealed and bent over an 8 thickness diameter. Welds made with M27 (7xxx series) material shall be bend tested within two weeks of welding. (This requirement is associated with the 7005 materials ability to substantially improve mechanical properties through natural aging, precipitation hardening at room temperature.) Welds made with F23 (4xxx series) filler metal on any M21, M22, or M23 (1xxx, 3xxx, 5xxx, or 6xxx series) material shall be bent in the same manner as M23 material. One other suggestion with regard to bend testing is to pay particular attention to the note provided within the AWS D1.2 aluminum code that states that the wraparound guided bend fixture is the preferred method of bend testing aluminum weldments Fig. 1. Although the plunger type guided bend test fixture is an option for use within the code, I suggest that you use the wraparound fixture, particularly for the higher-strength materials. As can be seen above, the special bend testing requirements for aluminum are rather extensive. I can assure you that if these requirements are not followed, there is a high probability that problems will be encountered during procedure qualification testing.

based on the annealed or overaged condition of the weld heat-affected zone (HAZ) dependent on whether welding the nonheat treatable or the heat-treatable aluminum alloys. Be aware that when welding the heat-treatable aluminum alloys, particularly the 6xxx series, care should be exercised to prevent the overheating of the base alloy during the welding process. Careful adherence to interpass temperature should be maintained, and preheating limits should be observed to prevent excessive welding temperatures. Consideration should be given to welding parameters, amps, volts, and travel speeds that govern heat input during the welding process. These parameters may need to be adjusted in order to lower the overall heat input during welding. The tensile strength of the HAZ of the heat-treatable alloys can be substantially lowered (to levels lower than that acceptable to the code) if welded with excessive heat input.

Conclusion
Yes, there are some differences between the AWS D1.1 and AWS D1.2 codes in terms of welding procedure qualification requirements. These differences are to be expected as they address the procedure qualification of two substantially different materials. It has been my experience that the two most common areas of difficulty experienced during the welding procedure development process for aluminum are associated with bend testing and tension tests, which I have listed above. There are also other issues such as porosity and incomplete fusion, which tend to be more prevalent in aluminum than in steel. However, these are more related to specific preweld preparation methods and welding techniques, and not directly associated with differences in code requirements.o

Reduced Section Tension Tests

One other item to consider is related to obtaining the minimum tensile strength requirements when conducting reduced section tension tests. Minimum tensile strength requirements for aluminum are

TONY ANDERSON is corporate technical training manager for ESAB North America. He is a Fellow of the British Welding Institute (TWI), a Registered Chartered Engineer with the British Engineering Council, and holds numerous positions on AWS technical committees. He is chairman of the Aluminum Association Technical Advisory Committee for Welding and author of the book Welding Aluminum Questions and Answers currently available from AWS. Questions may be sent to Anderson c/o Welding Journal, 550 NW LeJeune Rd., Miami, FL 33126, or via e-mail at tanderson@esab.com.