Selection and Weldability of Dispersion-Strengthened Aluminum Alloys

Conventional high-strength aluminum alloys produced via powder metallurgy (P/M) technologies, namely, rapid solidification (RS) and mechanical alloying (mechanical attrition) have high strength at room temperature and elevated temperature. This article focuses on the metallurgy and weldability of dispersion-strengthened aluminum alloys based on the aluminum-iron system that are produced using various RS-P/M processing techniques. It describes weldability issues related to weld solidification behavior, the formation of hydrogen-induced porosity in the weld zone, and the high-temperature deformation behavior of these alloys, which affect the selection and application of fusion and solid-state welding processes. The article provides specific examples of material responses to welding conditions and highlights the microstructural development in the weld zone.