The influence of pulsed gas metal arc welding on the fatigue and corrosion-fatigue properties of wrought aluminium 6061-T651

Purpose: This paper aims to characterise the hardness, tensile properties, corrosion behaviour and fatigue properties (in air and in a 3.5 per cent NaCl solution) of aluminium 6061-T651 in the as-received and as-welded conditions. Design/methodology/approach: Aluminium 6061-T651 plate material, prepared with double-V or square butt joint preparations was welded using semi-mechanised or mechanised pulsed gas metal arc welding. Magnesium-alloyed ER5356 or ER5183 filler material or silicon-alloyed ER4043 filler wire was used. The material was characterised in the as-supplied and as-welded conditions, and fatigue tests were performed in air and in a 3.5 per cent NaCl solution. The fatigue results were compared to the reference fatigue design curves for aluminium published in Eurocode 9 - Part 1-3. Findings: Significant softening, attributed to the partial dissolution and coarsening of precipitates, grain growth and recrystallisation during welding, was observed in the heat-affected zone (HAZ) of the 6061-T651 welds. During tensile testing, failure occurred in the HAZ of all 6061 welds tested. Welding reduced the room temperature fatigue life of all specimens evaluated. In 6061 welds, failure occurred preferentially in the softened HAZ of the welds. The presence of a corrosive environment (a 3.5 per cent NaCl solution in this investigation) during fatigue testing reduced the fatigue properties of all the samples tested. Corrosion pits formed preferentially at second phase particles and reduced the overall fatigue life by accelerating fatigue crack initiation. Originality/value: The fatigue properties of welded aluminium structures under dynamic loading conditions have been studied extensively. Welding is known to create tensile residual stresses, to promote grain growth, recrystallisation and softening in the HAZ, and to introduce weld defects that act as stress concentrations and preferential fatigue crack initiation sites. Several fatigue studies of aluminium welds emphasised the role of precipitates, second phase particles and inclusions in initiating fatigue cracks. When simultaneously subjected to a corrosive environment and dynamic loading, the fatigue properties are often adversely affected and even alloys with good corrosion resistance may fail prematurely under conditions promoting fatigue failure. The corrosion-fatigue performance of aluminium welds has not been systematically examined to date