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Many metals and thermoplastics can be welded, but some are easier to weld than others (see Rheological weldability). A material's weldability is used to determine the welding process and to compare the final weld quality to other materials. Weldability is often hard to define quantitatively, so most standards define it qualitatively.
Aluminium alloys are often used due to their high strength-to-weight ratio, corrosion resistance, low cost, high thermal and electrical conductivity.There are a variety of techniques to join aluminium including mechanical fasteners, welding, adhesive bonding, brazing, soldering and friction stir welding (FSW), etc. Various techniques are used based on the cost and strength required for the joint.
Typically, after welding, the properties near the weld are those of 6061-T4, a loss of strength of around 40%. The material can be re-heat-treated to restore near -T6 temper for the whole piece. After welding, the material can naturally age and restore some of its strength as well.
The primary disadvantages are their very high equipment costs (though these are decreasing) and a susceptibility to thermal cracking. Developments in this area include laser-hybrid welding, which uses principles from both laser beam welding and arc welding for even better weld properties, laser cladding, and x-ray welding. [46]
Using arc welding on pressure vessels requires 100 or more separate welds/cycles with additional processing for each cycle. Materials up to 200 mm thick can be welded in a single pass. Shrinkage is minimal (heat treatment is advisable). Welds avoid oxide or nitride contamination. The material retains strength better. The weld has fewer flaws/voids.
5059 aluminium alloy is an aluminium–magnesium alloy, primarily alloyed with magnesium.It is not strengthened by heat treatment, instead becoming stronger due to strain hardening, or cold mechanical working of the material.
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Aluminium–copper alloys (AlCu) are aluminium alloys that consist largely of aluminium (Al) and traces of copper (Cu) as the main alloying elements.Important grades also contain additives of magnesium, iron, nickel and silicon (AlCu(Mg, Fe, Ni, Si)), often manganese is also included to increase strength (see aluminium-manganese alloys).
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