Hot-Cracking Susceptibility
of 3004 A l u m i n u m
The susceptibility to hot cracking increases
as the Fe:Si ratio is decreased
BY W. F. SAVAGE, E. F. NIPPES A N D J. D. VARSIK
ABSTRACT. The hot-cracking suscepti-
bility of the 3004 Al alloy was investi-
gated w i t h use of the Varestraint test
and a microalloying process.
Microalloying is a process by which
the composition of a small part of a
plate can be altered by mixing another
alloy of nearly similar composition
into the plate by use of a GTA weld.
Using this process, the Fe and Si
contents of the 3004 alloy were varied
with little change in the other major
alloying elements.
The results of Varestraint tests
revealed that, as the Fe:Si ratio of the
3004 was decreased from 4.56 to 0.02,
the hot-cracking susceptibility in-
creased. Metallography revealed that
the increase in susceptibility resulted
from the development of a continuous
grain-boundary network which is ini-
tially dominated by (Mn, Fe) Al„ and fs
(Al-Mg) eutectic. Eventually, the (Mn,
Fe) Al e reverts to MnAI„ and is
replaced by a more continuous Mg2Si
as the Fe:Si ratio approaches zero.
Introduction
Alloy 3004 is a non-heat-treatable Al
alloy containing M n and Mg. It is
usually produced in sheets and plates
by the rolling of continuous-cast
ingots. Its good corrosion resistance is
reflected in its use in the fertilizer
industry for bulk storage tanks for a
solution of 83% N H 4 N 0 3 and in its use
as protection shelters for rapid-transit
station canopies. Because of its
strength and formability, it has been
suggested for use in passenger-car
bodies.
W h e n produced by continuous cast-
ing, the 3004 alloy requires greater care
and slower casting speeds than alloys
of higher alloy content in order to
reduce hot-cracking. Because of the
inherent hot-cracking tendency of the
3004 alloy, there is concern about the
effects of increasing (or decreasing)
the intermetallic-forming elements,
such as Fe and Si. These elements may
increase (or decrease) the amount of
intermetallic phases, alter the existing
phases, or possibly produce a lower
melting eutectic which might make
3004 more susceptible to hot-crack-
ing.
In Al alloys containing Fe and Si,
hot-cracking was found to increase
when the Fe:Si ratio was decreased
below 1.5.1'' Binary Al alloys contain-
ing up to 1% M n are usually free of hot
cracks under normal welding condi-
tions.
In Al alloyed with Si and M g , the
alloying elements preferentially com-
bine to form Mg„Si which has little
solubility in Al. A series of investiga-
tions'-" led to the following conclu-
sions:
1. Increasing the M g + Si content
w i t h constant Mg:Si ratio increased
hot-cracking.
2. At a constant M g + Si content,
the maximum hot-cracking occurred
at a Mg:Si atom ratio = 2:1 (wt
ratio = 1.74), and either increasing or
decreasing the Mg:Si ratio from this
value decreased hot-cracking.
3. Hot-cracking tendencies were a
W. F. SAVAGE is Professor of Metallurgical
Engineering and Director of Welding
Research and E. F. NIPPES is Professor of
Metallurgical Engineering, Rensselaer Poly-
technic Institute, Troy, New York; /. D.
VARSIK, former graduate student at RPI, is
now with Combustion Engineering, Wind-
sor, Connecticut.
W E L D I N G RESEARCH S U P P L E M E N T I 45-s
maximum at 1.0 wt-% Mg,Si.
Concerning the presence of Fe in Al
alloyed with Si and M g , Parker and
others concluded:"
1. Si combined preferentially w i t h
M g to form Mg^Si.
2. Fe formed FeAl,.
3. Mg.Si occurred predominantly in
the grain boundaries
4. When the Si content was kept
constant, increasing the Fe suppressed
the amount of Mg,Si present.
5. Increasing the amount of Si w i t h
constant Fe content had no effect on
the amount or the form of the Fe-rich
constituent.
Object
The objectives of this investigation
were:
1. To determine the feasibility of
using microalloying to prepare speci-
mens for Varestraint testing.
2. To study the influence of the
Fe:Si ratio on the hot-cracking suscep-
tibility of 3004 aluminum alloy.
Materials and Procedure
A novel method was utilized for
preparing a series of 3004 alloys which
w o u l d differ only in Fe:Si ratio. First, a
commercial lot of V2 in. (12.7 mm) 3004
plate containing 0.41 wt-% Fe and 0.09
wt-% Si (Fe:Si = 4.56) was chosen as a
master alloy and machined into 2 x 1 2
in. (51 X 305 mm) specimens for
Varestraint testing. 10 Two lots of mod-
ified 3004 composition, which differed
significantly in composition from that
of the master alloy only in the amount
of Fe and Si present, were then
prepared. As shown in Table 1, one lot
had 0.8 wt-% Fe and 0.3 wt-% Si
Table 1—Composition of As-Received
Material, wt-%
3004 Lot Lot
Alloy 390525B 390526A
Fe 0.41 0.80 0.01
Si 0.09 0.30 0.41
Cu 0.10 0.12 0.12
Mn 1.02 1.05 1.07
Mg 1.03 1.10 1.13
Cr 0.00 0.00 0.00
Ni - 0.00 0.00
Zn 0.01 0.01 0.00
Ti 0.02 0.01 0.01
B — 0.0002 0.0003
(Fe:Si = 2.67), and the other lot had
0.01 wt-% Fe and 0.41 wt-% Si
(Fe:Si = 0.024). These lots were cast in
the form of 0.25 in. (6.35 mm) diameter
bars w i t h a cross sectional area of
0.0491 in. 8 (31.7 mm-).
To prepare the series of microalloys
w i t h differing Fe:Si ratios, a 0.250 in.
(6.35 mm) wide groove w i t h a cross
sectional area of 0.0491 sq in. (31.7
mm-) was machined in each Vares-
traint test specimen and an insert of
modified composition was placed in
the groove. The insert was then fused
and mixed w i t h a portion of the
surrounding base metal by passing a
GTA weld along its length. A magneti-
cally oscillated GTA weld was then
passed along the resulting weld to
produce a controlled amount of addi-
tional dilution and mixing with the
base metal. In this fashion, a series of
" w e l d pads" were produced w i t h
essentially the same composition ex-
cept for the amounts of Fe and Si
present.
The specimens were then machined
flat and Varestraint tested. By proper
choice of welding conditions, the GTA
test weld and its heat-affected zone
(HAZ) were completely contained
w i t h i n the modified weld pad. Thus,
when the augmented strain was
applied in the usual manner, the crack-
ing produced during Varestraint test-
ing was confined within the weld pad
of modified composition. This proce-
dure for producing weld pads of
modified composition for Varestraint
testing will be referred to subsequent-
ly as "microalloying".
Microalloying Variables
The important factors in the mi-
croalloying procedure are: Cb = the
initial composition of the bar;
C r = the initial composition of the
insert rod; A,. = the initial cross sec-
tional area of the insert rod (a constant
0.0491 in.-', which is the same as that of
the U-groove machined in the bar);
Ap = the cross sectional area of the
microalloyed weld pad (controlled by
the welding conditions used in the
Table 2—Welding Conditions Used in Microalloying Process and Varestraint Test1"
Welding voltage, V
Welding current, A
Travel speed, ipm
Electrode extension, in. (mm)
Electrode-Work distance, in. (mm)
He shielding gas flow rate, cfh (litr
Same as above with:
Oscillation freq., Hz 1.67
Weld widths, in. (mm) 0.45 to 0.75 (11.4 to 19)
'"Electrode materials: W-2% ThO=, centerless ground Va in. (3.18 mm) diameter ground 90 deg included angle
microalloying passes).
The entire modified rod was fused
with the 3004 bar by choosing fusion-
pass conditions which gave a flat,
smooth surface, free of undercut or
overlap. The cross sectional area of
each microalloyed weld pad was
measured from an etched transverse
cross section of the Varestraint test
specimen.
The dilution, d, is defined as
d = A,,/A r . By the law of mixing
(assuming no losses), the theorectical
composition of the weld pad, C„,
could then be calculated as follows:
1 protective atmosphere was no longer
V needed. Thus, the chamber was
c„= ^c + n-j) c„
In this investigation, it was decided
to aim for Fe:Si values of 0.02, 0.8 to
1.40, 2.67, 3.1 to 3.4, and 4.56 using the
microalloyed weld pad technique and
the three as-received lots of Al test
bars.
Microalloy Welding Procedure
Initially, four problems were en-
countered in microalloying the 3004
bar material:
1. Development of a satisfactory
technique for deoxidizing and clean-
ing the Al.
2. Development of techniques for
preventing contamination of the weld
pad w i t h oxygen entrapped between
the insert rod and the groove in the
base plate.
3. Provision of an adequate heat
sink.
4. Prevention of distortion of the
bar during microalloying.
For the fusion pass, the last three
problems were solved by using a
water-cooled, Al restraining fixture
with a Plexiglas cover. The 3004 bar to
be microalloyed was tightly clamped
against the water-cooled base with
two Al side bars, each secured to the
fixture by three bolts. A fixed Plexiglas
cover enclosed this entire fixture to
form an atmosphere chamber. The top
of the Plexiglas cover had a narrow
Unoscillated
fusion passes Varestraint
17 16
230 165 ± 5
8 8
VA (19) % (19)
automatic %-2 (2.4)
3er minute) 70 (33) 70 (33)
Oscillated
microalloying
passes
opening in which an Al sheet twice as
long as the cover could slide.
A hole in the Al sheet allowed the
GTA torch to penetrate the atmo-
sphere chamber. During welding, the
nozzle pushed the Al sheet along the
top of the Plexiglas cover, thus provid-
ing a movable seal at the top of the
chamber. The chamber was flushed
w i t h He for 5-6 minutes (min) at 40 cfh
(19 liters/min) to displace air, and a
positive pressure was maintained dur-
ing the fusion pass to protect the
weld.
Once the insert was fused, the
removed and the microalloying passes
were performed using only the shield-
ing provided by the torch.
If the insert and bar were improperly
cleaned, an oxide barrier interfered
w i t h the wetting action and caused
undercutting, balling and lack of
fusion of the insert. Several oxide-
removal techniques were employed;
the most successful was a 10 min
immersion at room temperature in a
1.2 wt-% H.jSiF,; aqueous solution
containing 0.1% sodium lauryl sulfate,
a wetting agent." W h e n specimens
were degreased w i t h acetone, treated
with the H,SiF„ solution, wiped w i t h
acetone, and or dried, excellent wet-
ting action was obtained during the
fusion pass.
Table 2 summarizes the welding
conditions used in the fusion and
microalloying process. In this proce-
dure, t w o fusion-weld passes were
superimposed. The first, made in the
atmosphere chamber, fused the insert
w i t h the 3004 bar. The second assured
complete mixing, provided a uniform
depth of penetration along the alloyed
bar, and produced a smooth weld
contour nearly flush w i t h the original
plate surface. After the initial fusion
pass, the material was cleaned and
deoxidized with the H,SiFH solution,
and the second pass was made in the
opposite direction w i t h o u t the Plexi-

46-s I FEBRUARY 1979

glas a t m o s p h e r e c h a m b e r . W h e n l o w
v a l u e s o f d i l u t i o n w e r e r e q u i r e d in
o r d e r t o o b t a i n l o w v a l u e s o f Fe:Si, t h e
arc v o l t a g e of t h e s e c o n d pass w a s
l o w e r e d t o 15 V.
W e l d Oscillation
O s c i l l a t i n g t h e arc e l e c t r o m a g n e t i -
cally p r o v i d e d a means for increasing
t h e d i l u t i o n a n d m i x i n g o f t h e insert
w i t h t h e base m e t a l . T h e m a g n e t i c
oscillator used was a w a t e r - c o o l e d
C y c l o m a t i c P r o b e N u m b e r 4604. T h e
peak-to-peak voltage of the square
w a v e a p p l i e d to the oscillator was
varied to c o n t r o l the w e l d dimensions
a n d w a s m e a s u r e d w i t h t h e a i d of a
cathode-ray oscilloscope.
Because t h e a l l o y i n g insert h a d b e e n
p o s i t i o n e d in a U - g r o o v e m a c h i n e d in
t h e 3004 bar, t h e d e p t h o f p e n e t r a t i o n
of t h e initial fusion w e l d was deeper
than that of a simple b e a d - o n - p l a t e
w e l d . Thus, w i t h the w e l d i n g c o n d i -
t i o n s used ( T a b l e 2), a n y i n c r e a s e in
d i l u t i o n was d e p e n d e n t u p o n increas-
ing the w i d t h , since the original w e l d
was deeper t h a n the s u p e r - i m p o s e d
weave-bead weld.
Fig. 1—Cross section of a typical microal-
loyed specimen with (A) the initial fusion
weld, (B) weave weld, and (C) Varestraint
test weld, HF etch, X 6 (reduced 50% on
reproduction)
Varestraint Testing
O n c e the microalloying was c o m -
p l e t e d a n d the surface m a c h i n e d flat,
Varestraint testing was p e r f o r m e d .
T h e V a r e s t r a i n t test 1 " is a m e a n s o f
evaluating the hot-cracking tenden-
cies of a w e l d m e n t b y a p p l y i n g an
a u g m e n t e d l o n g i t u d i n a l s t r a i n to a
specimen during welding. The aug-
m e n t e d s t r a i n i n t h e o u t e r f i b e r s is
a p p r o x i m a t e d by the relationship:
e = — x 100% w h e n t < < R
2R
where e = longitudinal augmented
strain in %; t = t h i c k n e s s o f t h e test
p i e c e ; R = r a d i u s of c u r v a t u r e o f t h e
curved die surface.
I n t r o d u c i n g curved dies w i t h differ-
ent radii provides a means of varying
t h e m a g n i t u d e of t h e augmented
s t r a i n . H o t c r a c k i n g , if p r e s e n t , o c c u r s
a r o u n d t h e w e l d p o o l w h e n t h e strain
is a p p l i e d . T h e r e l a t i v e i n t e n s i t y of
c r a c k i n g is best e v a l u a t e d b y m e a s u r -
ing the length of each crack and
s u m m i n g to o b t a i n the total crack
l e n g t h p r o d u c e d by each level o f
a u g m e n t e d strain.
To i m p l e m e n t this process, a speci-
men was removed from the w e l d ,
m o u n t e d in e p o x y , g r o u n d flat, p o l -
i s h e d , a n d e t c h e d w i t h Keller's r e a g e n t
t o reveal t h e c r a c k i n g . T h e t o t a l c r a c k
l e n g t h w a s t h e n p l o t t e d against t h e %
a u g m e n t e d strain. The w e l d i n g c o n d i -
t i o n s used d u r i n g Varestraint testing
are s u m m a r i z e d in T a b l e 2. T h e Vares-
traint welds w e r e made w i t h a lower
e n e r g y i n p u t in o r d e r t h a t t h e y b e
entirely contained w i t h i n the microal-
loyed z o n e p r o d u c e d by the w e a v e -

Table 3 - Q u a n t o m e r i c Analysis, Standard Deviation, Fe:Si Ratio and Total Crack Length of Varestraint Test on Microalloyed 3004

Specimen
ident. Fe Si Fe:Si TCL, in.

50.25 0.58 0.03 0.20 0.02 2.94 0.04

56.25 0.56 0.03 0.17 0.02 3.23 0.00
50.33 0.58 0.06 0.20 0.03 2.99 0.071
57.33 0.56 0.01 0.18 0.01 3.04 0.059
50.50 0.52 0.01 0.18 0.01 2.99 0.224
52.50 0.53 0.03 0.19 0.02 2.86 0.152
501.0 0.56 0.05 0.18 0.02 3.08 0.189
521.0 0.53 0.01 0.17 0.01 3.09 0.224
561.0 0.53 0.01 0.17 0.01 3.18 0.209
502.0 0.58 0.01 0.19 0.01 3.09 0.402
522.0 0.58 0.03 0.18 0.01 3.16 0.413
562.0 0.58 0.04 0.20 0.01 2.90 0.465
504.0 0.59 0.02 0.18 0.01 3.18 0.854
524.0 0.59 0.08 0.20 0.02 2.89 0.776

I: e:Si 3.04
o" 0.12

60.25 0.25 0.03 0.23 0.01 1.10 0.044

60.33 0.26 0.01 0.23 0.01 1.16 0.087
67.33 0.28 0.03 0.25 0.02 1.13 0.157
66.50 0.28 0.02 0.23 0.01 1.20 0.322
602.0 0.25 0.03 0.23 0.02 1.10 0.846
604.0 0.27 0.03 0.22 0.02 1.25 1.035
624.0 0.26 0.01 0.22 0.02 1.24 1.102

I: e:Si 1.17
ef 0.065

62.25 0.29 0.03 0.19 0.01 1.51 nil

66.25 0.32 0.03 0.19 0.02 1.68 0.018
63.33 0.28 0.01 0.21 0.01 1.37 0.087
60.50 0.29 0.01 0.21 0.02 1.36 0.252
62.50 0.27 0.02 0.20 0.01 1.37 0.322
622.0 0.31 0.06 0.18 0.04 1.69 1.020
662.0 0.30 0.03 0.20 0.02 1.53 0.783
I: e:Si 1.50
o" 0.14

WELDING RESEARCH S U P P L E M E N T I 47-s


Table 4—Varestraint Test Result; on the Three As-Received Lots
Lot Strain, %
3004 0.25
0.33
0.50
1.00
2.00
4.00
390525B 0.25
0.33
0.50
390526A 0.33
0.50
1.00
bead.
The surfaces of the bar stock from
lots 390525B and 390526A were pre-
welded prior to Varestraint testing
using the same conditions employed
for microalloying to produce a weld
pad w i t h the same solidification sub-
structure. The as-received 3004 was
tested in the as-received, cast condi-
tion.
Determining Composition of Microalloyed
Weld Pads
After completion of each Varestraint
test, the specimen was removed and
prepared to reveal the transverse cross
section of the weld. Figure 1 shows:
1. The original weld A, w h i c h c o m -
bined the filler w i t h the base metal,
2. The weave-bead weld B, which
was used to control d i l u t i o n , and
3. The final Varestraint test weld C.
Note that the Varestraint test weld was
located entirely within the weave-
bead weld used to produce the
content, the Fe:Si ratio, and the total
crack length (TCL) for each microal-
loyed specimen subjected to the
Fe, wt-% Si, wt-% Fe:Si TCL (in.)
Varestraint test. Also shown is the
0.41 0.09 4.56 nil standard deviation for each set of four
nil spectrographic analyses used to deter-
0.133 mine the Fe and Si contents of a
0.200 specimen.
0.335 The first digit of the specimen
0.504
number identifies the insert material.
0.80 0.30 2.67 0.01
A " 5 " indicates the insert was from Lot
0.10
0.122 390525B and a " 6 " indicates the insert
0.01 0.41 0.02 0.37 was from Lot 390526A. The second
0.87 digit indicates the peak-to-peak vol-
2.06 tage applied to the oscillator coil. The
remaining numbers and the decimal
point indicate the augmented strain
microalloyed pad. used.
Theoretically, both the Fe and Si Attention is drawn to the fact that
composition can be calculated using using a constant insert diameter and
the rule of mixtures after first deter- altering the oscillator voltage to vary
mining the cross sectional areas of the the weld width did not provide a
welds. Spectrographic chemical ana- reliable method of varying composi-
lyses of these welds were performed at tion of the microalloyed weld pads for
the Alcoa Research Center; four ana- the three Al lots used. Note, for exam-
lyses were made on each weld pad ple, that specimens 502.00, 522.00, and
produced by the weave-bead. Of the 562.00, made w i t h weaving conditions
32 F e analyses, 17 calculated values which resulted in weld widths of 0.45,
were lower and 11 were higher than 0.53, and 0.70 in. (11.4 13.5, and 17.8
the spectrographic analysis by mm), respectively, had identical Fe
amounts ranging from —27 to +8%. Of contents and no significant difference
the 32 Si analyses, 18 calculated values in Si content. Thus, all the microal-
were lower and 9 were higher than the loyed specimens made w i t h Lot
spectrographic analyses by amounts 390525B inserts can be grouped in a
ranging from —26 to +28%. The single population w i t h a mean Fe:Si
remaining values in each instance ratio of 3.04 w i t h a standard deviation
agreed exactly. of 0.12.
The specimens microalloyed w i t h
Results and Discussion Lot 390526A can be grouped into t w o
populations as indicated in Table 3.
Microalloying Results
One group has a mean Fe:Si ratio of
Table 3, based upon spectrographic- 1.17 w i t h a standard deviation of 0.065;
analysis data, summarizes the Fe and Si the other, a mean Fe:Si ratio of 1.50

1000 I000 1

CO
co
<>
800 800
F s S i Ratio=4.56
X FetSi Ratio = 3 . 0 4 i *
T C L = 0.3l + 0.24Lne
TCL = 0.25+O.I6Ln£ z
<s> r2 = 0 . 8 5 7
r2 = 0 . 9 4 2 UJ
UJ
_l 600 600
_: o
c_> <) <>
< <
cc o /\ ti
o 400 400
_1
<
I- o
o <> fj
200
200 Cl (>
o I-
£/
-4- 01 0.2 0.4 0.6 I 4 6 8 10
O.I 0.2 0.4 0.6 I 6 8 IO
. ^ A U G M E N T E D STRAIN, %
e = AUGMENTED S T R A I N , % Fig. 3—Varestraint test result for microalloyed 3004 for the
Fig. 2—Varestraint test results for as-received 3004; Fe:Si = 4.56 Fe:Si = 3.04 population

48-s I FEBRUARY 1979

 1000 1200
CO
_J /
_* CO

x~ 800 _» 1000
/
Fe:Si Ratio = 2.67
I-
<_> TCL =0.24 O.I5Ln£ x"
UJ r 2 =0.8l H
_J
600 o
j_ •z.
o Fe.-Si Ratio = 1.50
< UJ 8 0 0 TCL = 0.89 + 0.44Lne
cc _:
o o r2 = 0.967
400 <
_J tr /
< U 600 ! 1
/
I-
o
II 200
_l 400
u
i i o )
0.2 0.4 0.6 6 8 IC 200
/
/
€=AUGMENTED STRAIN, %
Fig. 4—Varestraint test results for as-received lot 390525B; /
Fe:Si = 2.67 W
0.1 0.2 0.4 0.6 6 8 10

CO
IU0U
i
2C 0 0
€ = AUGMENTED STRAIN, %
Fig. 5—Varestraint test results for microalloyed 3004 for the
0
Fe:Si = 1.50 population
, 1
800 Fe.-Si Ratio = 0.02 1000
O TCL= 1.97+1.49 Lne
Z
LU r2 = 0.994
600
/ <> /
_: 2
o _ 800
FetSi Ratio = U7
< x" TCL = 0.5 6 4-0.38 Ln£
o /
t-
CP r2 = 0.995
400
UJ
_l 600
o _:
o
200 1 <
or
o ° 400
I-
/
Ql 0.2 0.4 0.6 6 8 10 o
F- 2 0 0
£ = AUGMENTED STRAIN, %
Fig. 7—Varestraint test results for as-received lot 390526A; 0
Fe:Si = 0.02
_L_L
0.2 0.4 0.6 I 2 4 6 8 10
Fig. 6—Varestraint test results lor microalloyed 3004 for the
Fe:Si = 1.17 population £ = AUGMENTED STRAIN, %

with a standard deviation of 0.14.
Varestraint Test Results
In addition to tests performed on
the three populations above, Vares-
traint tests were performed on as-
received 3004 and on plate material
produced from both Lots 390525B and
390526A. Table 4 summarizes the Fe
and Si contents, the Fe:Si ratio, and the
total crack length data from these
specimens.
Figures 2 through 7 summarize the
Varestraint test data in graphical form.
The total crack lengths in Tables 3 and
4 are plotted against the logarithm of
the augmented strain for each con-
stant Fe:Si ratio population. The Fe:Si
ratios in Figs. 2 through 7 are 4.56, 3.04,
2.67, 1.50, 1.17, and 0.02, respectively.
Also indicated on each plot is an
equation for the total crack length
(TCL) as a function of % augmented
strain obtained by least-squares analy-
sis of the data. The goodness-of-fit
parameter (r2) is also shown. A perfect
correlation w o u l d yield an r- value of
1.0. Both the absolute values and rela-
tive slopes of the plotted data indicate
that as the Fe:Si ratio decreases from
4.56 to 0.02, the hot-cracking suscepti-
bility of 3004 increased continuously at

W E L D I N G RESEARCH S U P P L E M E N T I 49-s
 2 . 0 *I _.u

CD
1.5
A = 0 . 6 9 - 0 . 3 3 LnR
r- B=0.49-0.25LnR
r2 = 0.98 Z
\ UJ
r*=0.98
UJ o 1.0
u \ LL.
L_
u_
u. » UJ
[_l o
o o
o 0.5
0.5
•**^—
• •
• * _____ 1 g
1.0 2.0 3.0 4.0 5.0
0.0 2,0 3.0 4,0 5.0
R=Fe:Si RATIO
R=Fe:Si RATIO Fig. 9—Relationship between the Coefficient B and the Fe:Si ratio

Fig. 8—Relationship between the coefficient A and the Fe:Si ratio

an i n c r e a s i n g rate.
Figures 8 a n d 9 s h o w t h e c o e f f i c i e n t s
A a n d B, r e s p e c t i v e l y , t a k e n f r o m t h e
TCL e q u a t i o n s p r e s e n t e d in Figs. 2
t h r o u g h 7 ( T C L = A + B Ine) p l o t t e d
against c o r r e s p o n d i n g Fe:Si
N o t e t h a t t h e best least-squares fit
corresponds to a negative coefficient
f o r t h e l o g a r i t h m i c t e r m in b o t h cases.
T h i s i n d i c a t e s a n e x p o n e n t i a l increase
in T C L w i t h a d e c r e a s i n g Fe:Si r a t i o .
N o t e t h a t f o r Fe:Si r a t i o s g r e a t e r t h a n
1.0 t o 2.0, t h e e f f e c t o f Fe:Si o n b o t h
c o e f f i c i e n t s is r e l a t i v e l y g r a d u a l . H o w -
ever, as Fe:Si is d e c r e a s e d b e l o w 1.0
the slope o f b o t h curves approaches
infinity. By c o m b i n i n g t h e least-
squares-fit equations f o r t h e t w o coef-
f i c i e n t s as a f u n c t i o n o f Fe:Si ratio w i t h
that f o r TCL vs. % a u g m e n t e d s t r a i n ,
t h e f o l l o w i n g g e n e r a l i z e d e q u a t i o n is
obtained:
TCL 0.69-0.33 In R + (0.49 - 0.25
InR) Ine
Table 5 summarizes t h e TCL values
calculated w i t h this e q u a t i o n for
s e l e c t e d v a l u e s o f Fe:Si r a t i o , R, a n d
a u g m e n t e d s t r a i n , e. T h e r e f o r e , a l -
though the microalloying process
f a i l e d t o o b t a i n a f u l l r a n g e o f Fe:Si
ratios b e t w e e n 0.02 a n d 4.56, t h e six
p o p u l a t i o n s tested p r o v i d e d e n o u g h
Table 5 - C a l c u l a t e d Total Crack Length in
Inches as a Function of Fe:Si Ratio and
Augmented Strain
Fe:Si
Ratio 0.33 0.5 1.0 2.0
i n f o r m a t i o n t o f o r m u j a t e an a p p r o x i - In a n y e v e n t , n o c o r r e l a t i o n w a s f o u n d
m a t e e x p r e s s i o n rela'ting T C L t o Fe:Si b e t w e e n v a r i a t i o n s in M g c o n t e n t a n d
ratio. the hot-cracking susceptibility.
Hot-Cracking Susceptibility of the
As-Received 3004 Relative to Other
The Variation in Magnesium
ratios. A l u m i n u m Alloys
T h e s p e c t r o g r a p h i c analyses o f t h e
m i c r o a l l o y e d test bars r e v e a l e d an Figure 10 c o m p a r e s total crack
erratic v a r i a t i o n i n t h e M g c o n t e n t . l e n g t h d a t a f o r t h e a s - r e c e i v e d 3004
The n o m i n a l M g c o m p o s i t i o n o f t h e (Fe:Si = 4.56) w i t h TCL d a t a f o r Fe:Si
a s - r e c e i v e d 3004 L o t , Lot 390525B, a n d ratios o f 0.1 a n d 1.0 as c a l c u l a t e d f r o m
Lot 390526A w e r e 1.03, 1.10. a n d 1.13 t h e a b o v e e q u a t i o n a n d T C L data f o r
wt-%, respectively. four o t h e r Al alloys. T h e most n o t a b l e
The spectrographic data in s o m e f e a t u r e o f Fig. 10 is t h a t b o t h t h e
cases r e v e a l e d t h a t w i t h i n t h e same a s - r e c e i v e d 3004 a n d t h e h y p o t h e t i c a l
w e l d , the M g c o m p o s i t i o n varied from a l l o y w i t h an Fe:Si r a t i o o f 1.0 e x h i b i t
0.79 t o 1.53 w t - % . M a g n e s i u m c o m p o - s i g n i f i c a n t l y less h o t - c r a c k i n g s u s c e p -
s i t i o n h i g h e r t h a n t h e n o m i n a l level tibility than any of the other f o u r
m u s t result f r o m s e g r e g a t i o n . A p p a r - c o m m e r c i a l heats t e s t e d . ' - T h e h y p o -
ent r e d u c t i o n s in M g c o n t e n t c o u l d , t h e t i c a l 3004 a l l o y w i t h an Fe:Si r a t i o o f
h o w e v e r , result f r o m e i t h e r segrega- 0.1 w o u l d , a c c o r d i n g t o Fig. 10, be
t i o n o r d e p l e t i o n b y o x i d a t i o n as a s u p e r i o r t o 7039-T6 a n d 2014-T6 in
result o f a t m o s p h e r i c c o n t a m i n a t i o n . h o t - c r a c k i n g resistance, b u t inferior to
4.0
CO
UJ
X
u 3.0
7039-T6
X
r-
_)
2.
UJ 2.0
_l
sc
o
<
cr I.O
o
4.0

0.1 0.27 0.71 1.45 2.19 2.93 _J

0.2 0.23 0.60 1.22 1.84 2.46 3004
° F e ; S i = 4.56
0.4 0.20 0.49 0.99 1.49 1.99 O
0.8 0.16 0.39 0.75 1.14 1.52 0.0 0.25 050 0.75 I.OO I.25
1.0 0.15 0.35 0.69 1.03 1.37
1.5 0.13 0.29 0.56 0.83 1.09
3.0 0.09 0.18 0.33 0.48 0.63
AUGMENTED STRAIN, %
4.5 0.07 0.I I 0.19 0.27 0.35 Fig. 10-Comparison ol Varestraint test results of as-received 3004 and microal-
loyed 3004 with other aluminum alloys

50-s I FEBRUARY 1979


F/'g. 11—Panorama of the 3004 base metal: Oscillated weld fusion zone (A-A) and oscillated weld fusion zone—Varestraint test weld (B-B) for a
microalloyed material with an Fe.S't ratio of 1.24. Notice crack arrest within oscillated fusion zone. Etched with 10% NaOH, X 75. (reduced 32%
on reproduction)
5083-0 and 6061-T6.
Metallographic examination of the
as-received 3004 confirmed the fact
that hot-cracking was intergranular in
both the fusion zone and HAZ. Some
of the hot cracks, notably in the HAZ,
had been back-filled or partially back-
filled by a liquid which solidified to
delineate the shape and path of the
once-separated grain boundary. Earlier
work at RPI'-"" has shown that materi-
al w h i c h back-fills a hot crack is of the
same composition as the last liquid to
solidify (or lowest melting eutectic).
When an almost continuous liquid
exists in the grain boundaries, the
narrow solid bridges cannot support
the applied strain, and a fissure is
formed. Once this happens, the
remaining liquid can be drawn in by
capillary action and subsequently so-
lidifies. If enough liquid is drawn in to
fill the crack completely, total healing
results, but if the volume of the crack
opening is larger than the volume of
liquid available, only partial healing
will occur. In an alloy such as 3004, the
amount of liquid available for crack
healing should then be related to the
amount of eutectic present in the
alloy.
Identification of the back-filled ma-
terial in the as-received 3004 was first
made metallographically, using a stan-
dardized series of etchants"'"' and
later verified w i t h electron-beam mi-
croprobe analysis at the Alcoa Techni-
cal Center. The back-filled eutectic
was identified as /3 (Al-Mg), and it
appears that the hot-cracking suscepti-
bility of the as-received 3004 is
influenced by the distribution of this
low-melting eutectic within the grain
boundaries.
Influence of Microalloyed Structure on
Varestraint Test Results
Figure 11 is a typical panorama of a
3004 alloy which has been microal-
loyed to provide a weave bead w i t h a
-
modified Fe:Si ratio of approximately
1.24. The surface shown is parallel to
the weld surface with the weave-
bead-to-base-metal interface located
at A-A and the weave-bead-to-Vare-
straint-test-weld interface at B-B. A
hot crack in the Varestraint-test weld
ends in the weave bead just to the
right of the Varestraint-test weld
fusion line. Thus, the crack-arresting
ability of the substructure in the
microalloyed region is evident.
In general, growth of the solid at the
solid-liquid interface in a weld tends
to occur parallel to the maximum
temperature gradient in the liquid.
This maximum gradient is usually
oriented perpendicular to the trailing
edge of the weld pool. W h e n the arc is
oscillated transverse to the welding
direction, the shape of the pool, the
instantaneous growth rate, and the
magnitude and direction of the tem-
perature gradient are altered w i t h each
excursion of the arc. This will cause
the corresponding modification in the
solidification substructure.
As seen in Fig. 11, the solidification
process within the weave bead is
disrupted periodically, and the growth
direction, as revealed by the solidifica-
tion substructure, changes several
times between A-A and B-B. Notice in
the vicinity of the Varestraint-test-
weld-fusion line that many of the cell
axes of the cellular dendrites are
almost parallel to the welding direc-
tion (parallel to B-B).
Because the weld cracking is inter-
granular and essentially transverse to
the test w e l d , crack propagation is
arrested because the solidification in
the weave bead is not oriented parallel
to the crack-sensitive grain boundaries
in the test weld. Furthermore, the
substructure in the weave bead at the
right of B-B is noticeably finer than
that in the test weld al the left of B-B.
The superposition of the Varestraint-
test weld replaces the original weave-
bead microstructure with a network of
W E L D I N G RESEARCH SUPPLEME NT I 51-s
"i •'
'K.
_i
.
• V,*.t
im-rY*> !*
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epitaxially grown grains whose bound-
aries curve in the direction of welding.
Thus, the hot cracks produced tend to
be normal to the fusion line at the
edge of the test weld and curve in the
direction of welding as they propagate
toward the centerline of the weld.
Microfissuring, which has been re-
ported 11 ' in multipass Al welds, from
eutectic melting or grain-boundary
liquation in underlying passes was not
observed during the microalloying
operation. However, introducing the
Varestraint-test weld caused cracking
in the weave beads with Fe:Si ratios in
the vicinity of 1.0. Such cracks at times
extended completely across the mi-
croalloyed weld pad on either side of
the Varestraint-test weld and arrested
abruptly at the weave-bead-to-base-
metal interface.
This behavior was pronounced in
test bars when a large augmented
strain was employed, when a low Fe:Si
ratio existed, and when a wide oscilla-
tion was used in microalloying. No
cracking of this sort was observed in
alloys with a high Fe:Si ratio. As is
discussed later, because some Subso-
lidus cracking was observed in the
weave bead, this cracking is thought to
be the result of a combination of
liquation and the coalescence of a
brittle phase in the grain boundaries.
Metallography of the Three As-Received
Lots
Because the concentration of all
other alloying elements was held
reasonably constant, the major differ-
ence among the three lots of plate
material studied can be attributed to
the variation in Fe and Si contents.
Metallography revealed the same con-
stituents were present in all three lots
but differed somewhat in both shape
and abundance. Phase identification
was accomplished by metallographic
techniques described by Keller and
W i l c o x " and Phragmen."
 Examination of the three as-
received lots revealed the presence of
(Mn, Fe) Al 6 and Mg 2 Si. It was noted
that:
1. The Fe content of the ( M n , Fe) Al 0
determined both the morphology and
abundance of this phase. W i t h a low
Fe content in the allov, the ( M n , Fe)
Al 6 reverts to MnAl 6 .
2. The distribution of the (Mn, Fe)
Al 6 influenced the distribution of the
Mg,Si w h i c h often shared the ( M n , Fe)
AI 6 -to-matrix interface.
3. When ( M n , Fe) Al„ was less abun-
dant or almost absent, the Mg2Si was
preferentially located along the grain
boundaries.
Examination of Back-filled Cracks in
Microalloyed and Modified Lots
As indicated previously, the back-
filled material in the hot cracks in the
as-received 3004 (Fe:Si = 4.56) was
identified as /? (Al-Mg) eutectic. Simi-
lar metallographic examination was
conducted on the back-filled cracks in
Varestraint-test specimens with Fe:Si
ratios of 0.02, 1.10, 2.67, and 2.87.
In each case, a sample containing
the location of the weld pool at the
instant of straining was removed,
mounted, and polished. A typical
back-filled crack was selected on the
as-polished surface of each specimen
for further inspection. The specimens
were then repolished, etched, and
examined using three different etching
procedures: Keller's Reagent, 10%
N a O H , and 20% H 2 SO J ."- ,r '
As an example, Fig. 12 shows the
appearance of a specimen with an
Fe:Si = 2.87 when etched w i t h 20%
HjSO„. In this case, the back-filled
material was identified as /3 (Al-Mg)
eutectic. This was also the case for all
other Fe:Si ratios examined. This met-
allographic identification was later
confirmed by electron-beam micro-
probe analysis.
The /3 (Al-Mg) eutectic is the lowest
melting constituent in 3004 and was
found to be present in all of the
compositions studied. Therefore, the
increase in hot-cracking susceptibility
observed at lower Fe:Si ratios cannot
be explained solely on the basis of this
constituent.
Examination of Hot Cracks in Low Fe:Si
Microalloyed 3004
In addition to an increase in hot-
cracking in the immediate vicinity of
the weld pool with an Fe:Si ratio of
1.05, there were numerous cracks
along the entire length of the weld.
The cracking initiated intergranularly
within the microalloyed weave bead
and propagated to the base-metal
boundary where the cracks were
arrested. Except for the cracks pro-
52-s I FEBRUARY 1979
duced at the solid-liquid interface at
the instant of straining, the cracking in
the fusion zone of the Varestraint-test
weld was transgranular and was not
associated w i t h the grain boundaries.
Hot-cracking, produced along the
trailing edge of the weld pool at the
moment the strain was applied, was
always intergranular even for the low
Fe:Si ratios. These hot cracks follow
paths well defined by a dark semi-
continuous phase, as shown in Fig. 13.
Notice that along the edges of the
crack, the grain-boundary constituent
appears to have been fractured w i t h
some particles remaining on opposite
sides of the cracks. The brittle phase is
^A?A'2-~
y The amount and distribution of the
' "_i** •*•
f.r
"ȣ&?__;
f ^^^^0
t- -.
Fig. 12—Backfilling in an alloy with
Fe.Si = 2.87; etched with 20% H,SO„ X500.
(reduced 50% on reproduction)
""_.*.*
Fig. 13-Enlarged area of tip ot a fusion-
zone hot-crack in a microalloy with an
Fe.Si = 1.05. Semi-continuous, grain-
boundary network with brittle (Mn, Fe) Al,,
constituent. Etched with 10% NaOH, X500.
(reduced 50% on reproduction)
Fig. 14—Fusion-zone solidification substruc-
ture in an alloy with an Fe:Si = 0.02. Etched
with 10% NaOH, x 150. (reduced 50% on
reproduction)
( M n , Fe) AI B , which is k n o w n to cause
grain-boundary weakness at high
strain levels in alloys w i t h less than
2.5% Mg. Although this constituent is
also found in the subgrain boundaries
as a discontinuous network, the con-
tinuous network at the grain bounda-
ries provides a preferential path for
crack propagation.
As the Fe:Si ratio is decreased to
0.02, similar grain-boundary networks
are present, as may be seen in Fig. 14.
The network becomes more nearly
continuous on both the grain and
subgrain boundaries as the Fe:Si ratio
is decreased. No cracking was ob-
served along the subgrain boundaries,
probably because the continuous, brit-
tle, grain-boundary films ruptured
first.
_-—"
(Mn, Fe) Al 6 constituent within the
fusion zone seems to determine the
dispersion of the Mg 2 Si. Figure 15
consists of bright-field and polarized-
light photomicrographs, respectively,
of the fusion zone in 3004 (Fe:Si =
4.56). Because no continuous grain
boundary film occurs, there is no
distinction between the subgrain and
grain boundaries with regard to the
distribution of (Mn, Fe) Al 6 or the
Mg.Si phases. The ( M n , Fe) Al„ is
uniformly dispersed and, as may be
seen in the polarized-light p h o t o m i -
crograph, so is the Mg 2 Si. At the lower
Fe:Si ratios, where the constituents
form a semi-continuous grain-bound-
ary film, the uniform dispersion in the
fusion zone is replaced by boundary
networks. Figure 16 consists of pho-
tomicrographs of a material w i t h an
Fe:Si ratio of 0.02 and shows semi-
continuous networks of MnAI 6 and
Mg,Si at the grain and subgrain b o u n d -
aries.
Thus, it appears that sequence of
metallographic changes observed in
the as-cast base metal also occurs
within the fusion zone:
1. At high Fe:Si ratios, the (Mn, Fe)
Al 0 is fairly uniformly dispersed in the
fusion zone and does not form contin-
uous networks at the grain and
subgrain boundaries. Thus, no prefer-
ential segregation of Mg2Si is ob-
served.
2. As the Fe content is decreased,
the ( M n , Fe) Al„ begins to form a
semi-continuous network in the grain
boundaries to produce a microstruc-
ture which is both brittle and suscepti-
ble to hot-cracking.
3. When the Fe content approaches
zero, the ( M n , Fe) Al 6 reverts to MnAI 6
and the Mg2Si forms a nearly contin-
uous network at the grain bounda-
ries.
The Fe:Si ratio at w h i c h the semi-
continuous grain-boundary network
begins to form could not be deter-
mined exactly from the limited n u m -

Fig. 15—Microstructure in the fusion zone
of as-received 3004 with an Fe:Si = 4.56. A
(top)—bright-field illumination, light gray
constiutent is (Mn, Fe) Al, and black con-
stituent is Mg.Si. B (bottom)—polarized
light illumination; dark gray constituent is
(Mn, Fe) Al,, and white constituent is Mg.Si.
As-polished, X500. (reduced 50% on repro-
duction)
bet of alloys involved in this investiga-
tion. However, brittle grain-boundary
networks appear to be present with
Fe:Si ratios slightly above 1.0, but are
absent when the ratio is 2.67 or
above.
This is consistent with the observed
cracking propensity both in the weave
bead where cracking is definitely
subsolidus, and in the Varestraint-test
weld where the cracking appears to
involve grain-boundary liquation.
Conclusions
"Microalloying" Experiments
1. It is possible to " m i x " t w o alumi-
num alloys w i t h different concentra-
tions of minor alloying elements with
a GTA weld to produce a microalloyed
strip of controlled intermediate com-
position.
2. Superimposing a weave weld on
the microalloyed weld pad failed to
produce the predicted range of com-
positions desired. However, three indi-
vidual populations were produced
within the theoretical range of mi-
croalloy compositions.
3. It is possible to conduct Vare-
stiaint tests of the modified composi-
tion by locating the test welds entirely
w i t h i n the microalloyed pad in order
to determine its hot-cracking suscepti-
bility.
3004 Varestraint Test Results
1. A mathematical expression was
formulated relating total crack length
to the Fe:Si ratio and percent aug-
mented strain.
2. The Varestraint Test data and the
related mathematical expression dem-
onstrated that as the Fe:Si ratio
decreases w i t h i n the 3004 alloy, hot-
cracking susceptibility increases.
3. As the Fe:Si ratio is decreased
from 2.0 to 1.0, the weld hot-cracking
susceptibility increases sharply and
becomes extremely high as the Fe:Si
ratio approaches zero.
Metallography of Microalloyed 3004 After
Varestraint Testing
1. At Fe:Si ratios greater than ap-
proximately 2.0, the hot-cracking sus-
ceptibility of 3004 results from the
presence of a low melting /? (Al-Mg)
eutectic distributed w i t h i n the grain
boundaries.
2. The amount of Fe in solid solu-
tion in the Al-Mn-Fe constituent, (Mn,
Fe) Al 6 , determines its abundance and
distribution within both the as-cast
base metal and the weld-fusion zones
of 3004.
3. As the Fe content decreases, the
( M n , Fe) AIG forms a semi-continuous
network at the grain boundaries. This
makes the grain boundaries more brit-
tle and hot-crack susceptible.
4. As the Fe content approaches
zero, the ( M n , Fe) Al„ reverts to MnAI 6
and becomes less abundant, and
Mg.Si forms a more continuous
grain-boundary network, presumably
explaining the further increase in hot-
cracking susceptibility.
5. There was no evidence of an Al-
Fe or Al-Fe-Si constituent in the 3004.
Acknowledgments
The authors wish to acknowledge
the financial support of the Alcoa
Foundation and to thank Richard K.
Sager, Douglas A. Granger and )an H.
L. VanLinden, members of the Alcoa
Technical Center, for their support and
assistance in completing this investiga-
tion.
References
1. Jennings and Pumphrey, "Hot Short-
ness of Some Al-Fe-Si Alloys of High Puri-
ty," ). Inst. Metals. V73, p. 273.
2. Lancaster, "Welding of Aluminum
Tanks for Experimental Reactors," British
Welding lournal. V4, p. 354. Aug. 1957.
3. Jennings and Pumphrey, "Considera-
tion of the Constitution of Al-Fe-Si Alloys
and Its Relation to Cracking Above the
Solidus," /. /nst. Metals. V74, p. 249, 1948.
4. Hull and Adams, "Review of Informa-
tion on Weld Cracking in Aluminum
Alloys," British Welding lournal. V1, p. 464,
Oct. 1954.
5. Capel, "Aluminum Welding Practice,"
British Welding lournal. V8, p. 245. May
1961.
WELDING RESEARCH SUPPLEMENT I 53-s
I
f -•
f-y.:
" i '
if t i ,
i
r
/
Fig. 16—Microstructure of the fusion zone
of a material with an Fe:Si = 0.02. A
(top)-bright-field illumination; semi-con-
tinuous network (black) is Mg.Si. B (bot-
tomj-polarized light illumination; semi-
continuous network (white) is Mg.Si. As-
polished, X1000. (reduced 50% on repro-
duction)
6. Dowd, |.D., "Weld Cracking of Alumi-
num Alloys," Welding lournal, 31 (10), Oct.
1952, Research Suppl., 448-s to 456-s.
7. Jennings, Singer, and Pumphrey, "Hot
Shortness of Some High Purity Alloys in the
Al-Cu-Si and Al-Mg-Si Systems," /. Inst.
Metals. V74, 1948, p. 227.
8. Dudas, J.H., and Collins, F.R., "Pre-
venting Weld Cracks in High-Strength
Aluminum Alloys," Welding journal, 45 (6),
lune 1966, Research Suppl., 241-s to 249-s.
9. Parker, Cox, and Turner, "Effect of Fe
and Si on Aluminum Alloy Test Bars,"). Inst.
of Metals. V73, p. 175, 1947.
10. Savage, W.F., and Lundin, CD., "The
Varestraint Test," Welding lournal, 44 (10),
Oct. 1965, Research Suppl., 433-s to 442-s.
11. Hess, W.F., Wyant, R.A., and Aver-
bach, B.L., "The Surface Treatment at Room
Temperature of Aluminum Alloys for Spot
Welding", Welding lournal, 23 (9), Sept.
1944, Research Suppl., 417-s to 435-s.
12. Savage, W.F., Nippes, E.F., and Lip-
pold, J.C, "An Investigation of Hot Crack-
ing in 5083-0 Aluminum Alloy Weldments,"
Welding journal, 56 (6), June 1977, Research
Suppl., 171-s to 178-s.
13. Savage, W.F., Nippes, E.F., and Miller,
T.W., "Microsegregation in 70 Cu-30 Ni.
Weld Metal," Welding journal, 55 (6). June
1976, Research Suppl., 165-s to 173-s.
14. Keller and Wilcox, "Identification of
Constituents of Aluminum Alloys," Alumi-
num Company of America, Technical Paper
No. 7. 1958.
15. Phragmen, "On the Phases Occurring
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