Heat-Treatable vs Non-Heat-Treatable Aluminum Alloys

Using Heat with Aluminum Alloys

In this article, you will learn about the differences between heat-treatable and non-heat-treatable aluminum alloys. The article also covers how the type of base alloy affects the final strength of the weld

Heat-Treatable and Non-Heat-Treatable are the two basic types of aluminum alloys. They are both widely used in welding fabrication. These alloys have distinct characteristics associated with their chemical and metallurgical structure and their reactions during the arc welding process.

Let us understand the basic differences between these two groups of alloys.

Non-Heat-Treatable Aluminum Alloys

The strength of these alloys is initially produced by alloying the aluminum with additions of other elements. These alloys consist of pure aluminum alloys (1xxx series), manganese alloys (3xxx series), silicon alloys (4xxx series), and magnesium alloys (5xxx series).

A further increase in strength of these alloys is obtained through various degrees of cold working or strain hardening. Cold working or strain hardening is accomplished by rolling, drawing through dies, stretching, or similar operations where area reduction is obtained. Regulating the amount of total reduction in the area of the material controls its final properties. Material that has been subjected to a strain-hardening temper may also be given a final, elevated temperature treatment called “stabilizing.” This is to ensure that the final mechanical properties do not change over time.

The letter “H” followed by numbers denotes the specific condition obtained from strain hardening.

The first number following the “H” indicates the basic operations used during or after strain hardening:

H1 – Strain hardened only

H2 – Strain hardened and partially annealed

H3 – Strain hardened and stabilized

The second number following the “H” indicates the degree of strain hardening:

HX2 – Quarter Hard

HX4 – Half Hard

HX6 – Three-Quarter Hard

HX8 – Full Hard

HX9 – Extra Hard

Heat-Treatable Aluminum Alloys

The initial strength of these alloys is also produced by the addition of alloying elements to pure aluminum. These elements include copper (2xxx series), magnesium and silicon, which can form the compound magnesium silicide (6xxx series), and zinc (7xxx series).

When present in each alloy, singly or in various combinations, these elements exhibit increasing solid solubility in aluminum as the temperature increases. Because of this reaction, it is possible to produce significant additional strengthening to the heat-treatable alloys. This is done by subjecting them to an elevated thermal treatment, quenching, and, when applicable, precipitation heat treatment also known as artificial aging.

Note: Because of additions of magnesium and or copper, there are also silicon(4xxx series) alloys that are heat-treatable.

In solution heat treatment, the material is typically heated to temperatures of 900 to 1050 °F, depending upon the alloy. This causes the alloying elements within the material to turn into a solid solution. Rapid quenching, usually in water, that freezes or traps the alloying elements in solution, follows this process.

Precipitation heat treatment or artificial aging is used after solution heat treatment. This involves heating the material for a controlled time at a lower temperature (around 250 to 400 °F). This process is used after solution heat treatment, which increases strength and stabilizes the material.

How Does the Type Of Material Effect the Weld Strength?

In short, the difference in transverse tensile strength of the completed groove weld is governed by the reaction of the base material to the heating and cooling cycles during the welding operation. The non-heat-treatable alloys are annealed in the heat-affected zone adjacent to the weld. This is unavoidable when arc welding, as we will reach the annealing temperature. The extended time at these temperatures is not required to anneal the base material.

Key Points to Consider When Welding Heat-treatable Alloys

The heat-treatable alloys are usually not fully annealed during the welding operation. They are subjected to a partial anneal and over the aging process. These alloys are very susceptible to time at temperature. The higher the temperature and the longer at temperature, the more significant the loss of strength in the base material adjacent to the weld. For this reason, it is important to control the overall heat input, preheating, and interpass temperatures when welding the heat-treatable alloys.

How Do 6061-T6 Heat-Treatable Base Alloys respond to Welding?

Typically, the common heat-treatable base alloys, such as 6061-T6, lose a substantial proportion of their mechanical strength after welding. For example, 6061-T6 typically has 45,000 PSI (Per Square Inch) tensile strength prior to welding and around 27,000 PSI in the as-welded condition. One option with the heat-treatable alloys is post-weld heat treatment to return the mechanical strength to the manufactured component. If post-weld heat-treating is considered, the filler alloy’s ability to respond to the heat treatment should be evaluated.

Most of the commonly used filler alloys will not respond to post-weld heat treatment without substantial dilution with the heat-treatable base alloy. This is not always easy to achieve and can be difficult to control consistently. For this reason, filler alloys have been developed to independently respond to heat treatment.  

Post Weld Heat Treatment in 4643 Filler Alloy

As an example, filler alloy 4643 was developed for welding 6xxx series base alloys and developing high mechanical properties in post-weld heat-treated conditions. This alloy was developed by taking the well-known alloy 4043, reducing the silicon, and adding 0.10 to 0.30 percent magnesium, this ensured its ability to unquestionably respond to post-weld heat treatment.