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welded aluminum components

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Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.aero.c0047636
EISBN: 978-1-62708-217-4
...Abstract Abstract Several elbow subassemblies comprising segments of oil-line assemblies that recycled aircraft-engine oil from pump to filter broke in service. The components of the subassemblies were made of aluminum alloy 6061-T6. Two subassemblies were returned to the laboratory...
Series: ASM Failure Analysis Case Histories
Volume: 2
Publisher: ASM International
Published: 01 December 1993
DOI: 10.31399/asm.fach.v02.c9001329
EISBN: 978-1-62708-215-0
... with well-defined area of dealloying. Etched Abstract Abstract Various aluminum bronze valves and fittings on the essential cooling water system at a nuclear plant were found to be leaking. The leakage was limited to small-bore socket-welded components. Four specimens were examined: three castings...
Series: ASM Handbook
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.a0006785
EISBN: 978-1-62708-295-2
... hydrogen-induced cracking; SSC, sulfide stress cracking; AGO, atmospheric gas oil; LVGO, light-vacuum gas oil; HVGO, heavy-vacuum gas oil. Adapted from Ref 6 Examples of components and industries that have experienced SCC failures include (this list is not exhaustive): Aerospace: Aluminum...
Series: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001829
EISBN: 978-1-62708-241-9
...-magnification micrographs of top/bond-coat interface of (c) 400 and (d) 721ES The operating environment caused high-temperature oxidation, hot corrosion, and low-cycle fatigue, thus producing serious degradation of hot components. The inner root area of 721ES had been regenerated by welding at once...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.aero.c0047677
EISBN: 978-1-62708-217-4
...Abstract Abstract Resistance spot welds joining aluminum alloy 2024-T8511 stiffeners to the aluminum alloy 6061-T62 skin of an aircraft drop tank failed during slosh and vibration testing. Visual examination of the fracture surfaces showed that the failure was by tensile or bending overload...
Series: ASM Handbook
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.a0006783
EISBN: 978-1-62708-295-2
... that can affect galvanic corrosion. (a) Fasteners should be more noble than the components being fastened; undercuts should be avoided, and insulating washers and spaces should be used to completely isolate the fastener. (b) Weld filler metals should be more noble than base metals. Transition joints can...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c9001150
EISBN: 978-1-62708-235-8
... carbon steel bars cut from rolled plate are welded to the scroll shaft approximately 70° from each other and at slightly different elevations. Three curved concentric steel stiffeners are welded to the bars, forming a skeleton similar to a turbine blade. Finally, aluminum screens, manufactured from...
Series: ASM Handbook
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.a0006786
EISBN: 978-1-62708-295-2
... Embrittlement Causes Aluminum Plate Heat Exchanger Failure, Mater . Perform. , Vol 37 ( No. 6 ), June 1998 , p 59 – 60 • Vergeldt E. , Junai A.A. , and Kolster B.H. , Liquation Cracking of High Strength Aluminum Alloy 7075 , Joining/Welding 2000 (Assemblage/Soudage 2000) , July...
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003554
EISBN: 978-1-62708-180-1
... • Vergeldt E. , Junai A.A. , and Kolster B.H. , Liquation Cracking of High Strength Aluminum Alloy 7075 , Joining/Welding 2000 (Assemblage/Soudage 2000) , 1–2 July 1991 (The Hague, the Netherlands ), Pergamon Press , Oxford, U.K. , 1991 , p 229 – 241 • Wright M.D...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.aero.c0047072
EISBN: 978-1-62708-217-4
... of an outer aerodynamic shell and an inner stiffener shell, both of 1.3 mm (0.050 in.) thick aluminum alloy 6061-T6, and four attachment clips of 1 mm (0.040 in.) thick alclad aluminum alloy 2024-T42. Each clip was joined to the outer shell by 12 spot welds and was also joined to the stiffener. Analysis...
Series: ASM Handbook
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.a0006778
EISBN: 978-1-62708-295-2
... as the cause of all overload failure, because it does not include failures in which embrittlement or other causes result in fracture under normal loading. The purpose of engineering failure analysis is to identify the root cause of component or system failure and to prevent similar occurrences. Underdesign...
Book Chapter

Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003548
EISBN: 978-1-62708-180-1
... of fatigue failure mode. Source: Ref 6 The seal had failed allowing moisture into the cavity. This served as an electrolyte for galvanic corrosion between the lead and aluminum components. Corrosion pits formed at contact points of the lead wool and the aluminum spar wall. These pits served...
Series: ASM Handbook
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.a0006760
EISBN: 978-1-62708-295-2
... referred to as transgranular, cracks cross grains, often with an apparently random path ( Fig. 7 ). Fig. 7 (a) Intergranular crack in Monel. (b) Transgranular crack in aluminum Fatigue cracks propagate in components subject to cyclic loading, iniating at a stress concentrator. The crack grows...
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003543
EISBN: 978-1-62708-180-1
... embrittlement or other causes result in fracture under normal loading. The purpose of engineering failure analysis is to identify the root cause of component or system failure and to prevent similar occurrences. Underdesign is just one potential cause of an overload failure, and the time-consuming...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.aero.c0047673
EISBN: 978-1-62708-217-4
...Abstract Abstract A series of resistance spot welds joining Z-shape and C-shape members of an aircraft drop-tank structure failed during ejection testing. The members were fabricated of alclad aluminum alloy 2024-T62. The back surface of the C-shape members showed severe electrode-indentation...
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003517
EISBN: 978-1-62708-180-1
... Abstract This article focuses on the life assessment methods for elevated-temperature failure mechanisms and metallurgical instabilities that reduce life or cause loss of function or operating time of high-temperature components, namely, gas turbine blade, and power plant piping and tubing...
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003553
EISBN: 978-1-62708-180-1
... the SCC, which occurs due to welding, metalworking process, and stress concentration, including options for investigation and corrective measures. It describes the sources of stresses in service and the effect of composition and metal structure on the susceptibility of SCC. The article provides...
Series: ASM Failure Analysis Case Histories
Volume: 1
Publisher: ASM International
Published: 01 December 1992
DOI: 10.31399/asm.fach.v01.c9001082
EISBN: 978-1-62708-214-3
... 2 Comparison of the composition of specimen base materials and weld repairs to AISI 304L specification requirements Component Composition, wt% C Mn P S Si Ni Cr Mo Cu V Nb Al Fe Specimen #4 0.03 1.57 0.023 0.017 1.19 11.6 17.9 <0.01 0.10 0.06 <0.005 0.01...
Series: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001812
EISBN: 978-1-62708-241-9
... sections (unetched) of the ruptured 5083-0 Al–Mg alloy inlet nozzle showing extensive intergranular cracking ( a ) in the weld, and ( b ) in the plate It was concluded from the above observations that failure had occurred by LME (by mercury). Mercuryinduced degradation of aluminum-alloy components...
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003509
EISBN: 978-1-62708-180-1
... and nondestructive inspection of welds is also described in Welding, Brazing, and Soldering , Volume 6 of ASM Handbook. Service failures of welds, similar to those of any other structural component, depend on the operating environment and the nature of the applied load and may include failures from...