Structural Engineering & Statics
where the load goes
Series

Heat-affected zone — the series

5 essays on one idea, from the one that introduces it to the one that assumes the rest.
  1. The strength was bought in a furnace and the welder gives it back. Proof stress as delivered and beside a weld, for four aluminium alloys. The heat-treated alloys lose half of it: the strength of a 6xxx extrusion is in precipitates formed by an ageing treatment, and the arc dissolves them for 32 mm either side of the weld, permanently. The work-hardened tempers lose nearly as much, because the heat undoes exactly the work. The annealed ones lose nothing at all, because there is nothing left in them to anneal. The consequence is the crossover: 5083-H22 is 1.04 times 6061-T6 as delivered and 0.92 times it once welded, so the stronger alloy is the weaker member. The 240 mm member drawn, with two longitudinal welds, keeps 87% of its parent capacity — a weld along a member softens a strip and leaves a section, and the same weld across it softens the whole of one.

    The strength the welder gives back

    A 6082-T6 extrusion is twice as strong as a 5083-H111 plate and, welded across, the two are within a few per cent of each other. The heat of the arc anneals the metal for thirty millimetres either side, permanently, and the strength that was bought in a furnace is given back at the first joint.

    part 1 · materials
  2. Ductile until it was welded. A 2.0 m 6082-T6 member pulled in tension, as supplied and with one weld across it whose heat-affected zone is 60 mm long: the load per unit of parent section against the member's overall strain, to the maximum load, where the weaker part begins to neck. The plain member reaches 310 N/mm² at 7.0% strain, 140 mm of stretch. The welded one reaches 185 N/mm² at 0.62%, 12.3 mm — 8.8% of the plain member's, and the parent never reaches its proof stress of 260 N/mm². (uniform elongations assumed: 7.0% for the parent, 12% for the zone)

    The soft zone that takes all the stretch

    The metal beside a weld in heat-treated aluminium is weaker than the rest of the member and more ductile, and it is tempting to read the second fact as a consolation. It is not. A member welded across stretches only where it is weak, and the weak zone is sixty millimetres long; a two-metre 6082-T6 tie that would extend 140 mm before necking extends 12 mm once welded, and the parent metal never yields at all. What decides it is one ratio, the zone's ultimate strength over the parent's, and the ductility returns only when that ratio reaches one.

    part 2 · materials
  3. A few per cent between two welds is most of the second one's stretch. For a 2.0 m 6082-T6 member with two welds whose heat-affected zones are each 60 mm long, the stretch beyond the elastic at maximum load as a multiple of one weld's (solid), against how much stronger the second zone is than the first; dashed, the share of its own uniform plastic strain the stronger zone reaches when the weaker peaks, (1/(1 + gap))ⁿ with the zone's hardening exponent n = 10.4. Identical zones give 2.00 times one weld's stretch; 1.74 at a gap of 3 per cent, 1.23 at 15. The stronger zone gives half its stretch at a gap of 7.1 per cent. (uniform elongation of the zone assumed at 12%, and each zone's proof stress and ultimate scaled together)

    Two welds, and the one that decides

    A member welded twice has two soft zones in series. If they were identical, both would reach their ultimate strength at the same load and the member would stretch twice as far as with one weld before either necked. They are never identical, and the flat top of an aluminium zone's stress–strain curve means that a second zone five per cent stronger than the first gives only sixty per cent of its stretch. Every weld added makes the member weaker, by the statistics of its weakest link, and more ductile, by less than it would if the welds matched.

    part 3 · materials
  4. The weakest weld is not the one straight across. The ultimate strength of a member of 6082-T6 (parent ultimate 310 N/mm², zone 185) whose heat-affected zone crosses it at every angle from along the load (0) to straight across it (90 degrees), as load over the gross section. Across the load the zone's neighbours stop it contracting, and it carries 214 N/mm², 15 per cent above its own uniaxial 185. At 54.7 degrees, the angle a free sheet necks along, they give it nothing and the member carries 185. Below 24.2 degrees the zone's own neck would need more than a section through the parent can carry, and the member reaches 278 — the strength it has with the zone, 25 per cent of the section, running along it. At 30 degrees, 237; at 70, 196.

    The weld that is weakest at fifty-five degrees

    A soft heat-affected zone that the load crosses fails by necking along its own line, and it can do that only if nothing along the line has to stretch. Straight across the load, the parent on either side stops the zone contracting and lends it 15 per cent. At 54.7 degrees — the angle a free sheet necks along — it lends nothing, and the member carries the zone's own strength. Below 24 degrees the zone cannot neck alone at all, and a weld running along the member costs a tenth of its strength while adding to its stretch.

    part 4 · materials
  5. What a 60-degree seam leaves of the wall. The combinations of axial stress σa and hoop stress σh that a tube of 6082-T6 (parent ultimate 310 N/mm², softened zone 185) carries, with its seam at 60° to the axis (solid), inside the parent wall's von Mises ellipse (dashed). Where the solid line falls inside the ellipse the seam's zone fails first. axial tension: 60 per cent of the parent; closed pressure: 78 per cent of the parent; hoop alone: 76 per cent of the parent. The seam is weakest, at 60 per cent, along the loadings whose unstretched line lies on it.

    The seam that pressure protects

    A soft weld zone pulled at 55 degrees to the load gets no help from the metal around it, because 55 degrees is the line a plate under uniaxial tension does not stretch. A spiral-welded tube winds its seam at about that angle. Pressurise the tube and the line that does not stretch moves to the tube's own axis, so the spiral seam is suddenly well protected and the longitudinal seam is the exposed one. The soft zone's weakness belongs to the loading as much as to the weld: a seam is in danger only where the field around it leaves its line unstretched.

    part 5 · materials

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