5052 Aluminum

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So I had a quick question about 5052 aluminum. I had never welded this type of alloy because most of the aluminum welding I have done was with 6061. Although I have had a few problems with 6061 hot cracking in the past, it has never been an ongoing issue. 5052 however, has been a different story. It seems like with the 5052, hot cracking becomes a more frequent problem (at least for me). I am using 4043 filler and I am wondering if the problem is that I should use another type of filler. I was just wondering if anyone knows if there is anything I can do to prevent hot cracking on 5052? Any help would be greatly appreciated. BEZInsanity: doing the same thing over and over again and expecting different results.
Reply:Hello BEZ, most of the time I would use 5356 to weld on that alloy. Yet, cracking with 4043 is somewhat odd considering that it is often substituted for other alloys where weld cracking is an issue. Which process are you using? GMAW, GTAW? If it is GTAW, be sure to use ample filler while making a particular weld, sometimes, the autogeneous welding(without filler) or dilution of a filler from not using enough, could contribute to a cracking problem. Be interested to hear a few more details or pictures of the issues you are experiencing. Good luck and best regards, Allanaevald
Reply:Originally Posted by aevaldHello BEZ, most of the time I would use 5356 to weld on that alloy. Yet, cracking with 4043 is somewhat odd considering that it is often substituted for other alloys where weld cracking is an issue. Which process are you using? GMAW, GTAW? If it is GTAW, be sure to use ample filler while making a particular weld, sometimes, the autogeneous welding(without filler) or dilution of a filler from not using enough, could contribute to a cracking problem. Be interested to hear a few more details or pictures of the issues you are experiencing. Good luck and best regards, Allan
Reply:Hello BEZ, look forward to an update on your progress. Another few questions: what sorts of thicknesses are you dealing with? what sort of joint configuration(fillet, outside corner, lap, butt)? If this is a deep V configuration or something similar? it is very common to end up with centerline cracking, particularly if the bead contour ends up being concave to any great degree. Also, is there a great amount of restraint to any of these weld set-ups?, can be a contributor there sometimes. Where I am located 5052 is often used for a number of marine applications and where the aluminum needs to be formed it is very forgiving and generally not too crack sensitive. That's one of the reasons that I find the issue you are having somewhat unusual. Again, good luck and best regards, Allanaevald
Reply:Originally Posted by aevaldHello BEZ, look forward to an update on your progress. Another few questions: what sorts of thicknesses are you dealing with? what sort of joint configuration(fillet, outside corner, lap, butt)? If this is a deep V configuration or something similar? it is very common to end up with centerline cracking, particularly if the bead contour ends up being concave to any great degree. Also, is there a great amount of restraint to any of these weld set-ups?, can be a contributor there sometimes. Where I am located 5052 is often used for a number of marine applications and where the aluminum needs to be formed it is very forgiving and generally not too crack sensitive. That's one of the reasons that I find the issue you are having somewhat unusual. Again, good luck and best regards, Allan
Reply:The over dilution of the filler would be not putting down enough filler and having the base metal overeally dilute the filler in the puddle  which can cause crackingMiller Xmt 350Lincoln Ln-25Ahp 200xSmith Gas Mixer AR/HTig is my Kung FuThrowing down dimes and weaving aboutInstagram http://instagram.com/[email protected]
Reply:Originally Posted by BEZ66I am actually using GTAW for this process and I am NOT welding without filler (autogeneous). I was also under the impression that 4043 was a good "all around" filler for a number of various aluminum alloys (with 5052 being one of them). Although I am not 100% sure that dilution isn't the problem, I don't think there is a lack of filler material. I will get a hold of some 5356 rod and try again. And maybe this time I will take some pictures before I throw the hot cracked aluminum pieces in the recycling bin... DOH!! Thanks for your help aevald!!
Reply:5356 here too. I understand it is more "elastic" than 4043. 4043 for me cracks as well.www.tjsperformance.comDynasty 300 DXHTP 240HTP Microcut 380Hyperthem 85JD2 Hyd Bender and HF Hyd Ring Roller all in one =(Frankenbender)Bpt. Mill/DRO4' x 8' CNC Plasma TableInstagram: tjsperformanceYT: TJS Welding and Fabrication
Reply:Hot cracking occurs when you get an alloying ingredient in certain ranges, which are generally small (like around 1-3%, depending on which ingredients are involved; see attached picture below)A general idea to avoid hot cracking is to select alloys being "mixed" so that none of the ingredients mixed into your weld puddle are potentially in crack sensitive portions.  Avoiding possibly mixing a crack sensitive alloy will pretty much eliminate hot cracking issues.5052 is an alloy of mostly aluminum, some magnesium (roughly some 2.5%), and pretty much no silicon.5356 is an alloy of most aluminum, some magnesium (roughly some 5%) and pretty much no silicon.4043 is an alloy of mostly aluminum, no magnesium, and some silicon (roughly some 5%).So, try 5356 filler, rather than 4043, to weld your 5052 parent metals.  The 5356 will keep the silicon in your weld puddle down sufficiently low from potentially getting mixed in that the crack sensitive area around .9%, the magnesium in your weld puddle sufficiently high to avoid it potentially being mixed it its crack sensitivearea around 1.1%, and not to mention the magnesium-silicide in your weld puddle sufficiently low from potentially getting mixed in its crack sensitive area around 1%.Using 4043, it's not surprised that you can potentially mix up some pretty crack sensitive ingredients.  (Although I've welded 5052 with 4043 before, and it can certainly be done.  There are other mixes that are a LOT more crack senstiive, like many Al-Cu alloys.)As a side benefit, 5356, especially used to weld 5052, is going to leave a really very strong and ductile weld deposit!  Try welding a 5052 test coupon with 4043 and another with 5356, and then try a destructive bend test.  (e.g., hammer or bend the welds in a vice)
Reply:Great post, Jakru. Never heard that info before. I'm saving this thread.