Статті в журналах: "Aluminum Cracking"

1

Field, D. P., H. Weiland, and K. Kunze. "Intergranular Cracking in Aluminum Alloys." Canadian Metallurgical Quarterly 34, no. 3 (July 1995): 203–10. http://dx.doi.org/10.1179/cmq.1995.34.3.203.

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2

Huang, C., G. Cao, and S. Kou. "Liquation Cracking in Aluminum Welds." Materials Science Forum 539-543 (March 2007): 4036–41. http://dx.doi.org/10.4028/www.scientific.net/msf.539-543.4036.

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Liquation cracking in the partially melted zone (PMZ) of aluminum welds was studied. The PMZ is the region immediately outside the fusion zone where the material is heated above the eutectic temperature. Highly crack-susceptible alloys 2024 and 7075 were welded using gas-metal arc welding (GMAW) with filler metals 1100 and 4043, respectively. Circular-patch welds were made on 3.2 mm thick workpiece with full penetration, and single-pass welds were made on 9.5 mm thick workpiece with partial penetration. Liquation cracking was observed in all welds. Dualpass welds were also made on 9.5 mm thick workpiece, with overlapping between the penetration tips of the two partial-penetration passes made on the opposite sides of the workpiece. Liquation cracking was found in the first pass but not in the second pass. The results were explained using TfS (temperature vs. fraction solid) curves of the weld metal (WM) and the PMZ based on the following criterion proposed recently: liquation cracking can occur if WM fS > PMZ fS during PMZ solidification.

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3

Jawan, Hosen Ali. "Some Thoughts on Stress Corrosion Cracking of (7xxx) Aluminum Alloys." International Journal of Materials Science and Engineering 7, no. 2 (June 2019): 40–51. http://dx.doi.org/10.17706/ijmse.2019.7.2.40-51.

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4

OHSAKI, Shuhei. "Stress corrosion cracking of aluminum alloys." Journal of Japan Institute of Light Metals 46, no. 9 (1996): 456–66. http://dx.doi.org/10.2464/jilm.46.456.

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5

Yang, Xiao, Xianfeng Zhang, Yan Liu, Xuefeng Li, Jieming Chen, Xinyao Zhang, and Lingqing Gao. "Environmental Failure Behavior Analysis of 7085 High Strength Aluminum Alloy under High Temperature and High Humidity." Metals 12, no. 6 (June 5, 2022): 968. http://dx.doi.org/10.3390/met12060968.

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High-strength aluminum alloys are exposed to more and more environmentally-induced cracking failure behaviors during service. However, due to the hard to detect nature of hydrogen, and the special working conditions, failure research has obvious hysteresis and complexity, and it is impossible to truly reflect the material failure phenomenon and mechanism. In this paper, 7085 high-strength aluminum alloy is selected as the research material to simulate and reproduce the environmental failure phenomenon of aircraft under extreme working conditions (temperature 70 °C, humidity 85%). The results proved that high-strength aluminum alloy has environmental cracking failure behavior under extreme working conditions. The failure mode that was determined was due to environment-induced hydrogen and hydrogen-induced cracking, which is the result of the combined action of hydrogen and stress. Meanwhile, we demonstrate that high-strength aluminum alloy’s environmental failure behavior in an environment of high temperature and high humidity is different from traditional stress corrosion cracking behavior.

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6

Duan, Cui Fang, Wei Li, and Ji Liang Zhang. "Aluminum Alloy Plate with a Hole Fracture Experiment and Numerical Analysis." Advanced Materials Research 568 (September 2012): 315–19. http://dx.doi.org/10.4028/www.scientific.net/amr.568.315.

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This article studies aluminum alloy plate through 16 to 3mm thick with a hole under room temperature fracture test. The experimental results show: the initial macroscopic crack initiation at the notch of the center of the surface, along the thickness direction through, then along the width direction of expanded rapidly until complete fracture. Specimen cracking load in the load - displacement curve of descent, less than the limit load. Test piece opening more and more sharp, fracture ductility worse. Perforated plate cracking load depends mainly on the cross-sectional area, does not depend on the gap ratio ( b/a ). The test of aluminium alloy sheets for fracture mechanism and fracture design provides a reliable test data.

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7

Venugopal, A., P. Ramesh Narayanan, S. C. Sharma, and Koshy M. George. "Effect of Micro Arc Oxidation Treatment on the Corrosion and Stress Corrosion Cracking (SCC) Behaviours of AA7020-T6 Aluminum Alloy in 3.5% NaCl Solution." Materials Science Forum 830-831 (September 2015): 639–42. http://dx.doi.org/10.4028/www.scientific.net/msf.830-831.639.

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Alumina coating was formed on AA7020 aluminum alloy by micro arc oxidation (MAO) method and its corrosion and stress corrosion cracking (SCC) behaviors were examined in 3.5 wt. % NaCl solution. Potentiodynamic polarization (PP) was used to evaluate the corrosion resistance of the coating and slow strain rate test (SSRT) was used for evaluating the environmental cracking resistance in 3.5% NaCl solution. Results indicated that MAO coating on AA7020 alloy significantly improved the corrosion resistance. However the environmental cracking resistance was found to be only marginal. Key words: aluminum, micro arc oxidation, x-ray diffraction, stress corrosion cracking

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8

Zhang, Fan, Songmao Liang, Chuan Zhang, Shuanglin Chen, Duchao Lv, Weisheng Cao, and Sindo Kou. "Prediction of Cracking Susceptibility of Commercial Aluminum Alloys during Solidification." Metals 11, no. 9 (September 17, 2021): 1479. http://dx.doi.org/10.3390/met11091479.

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Cracking during solidification is a complex phenomenon which has been investigated from various angles for decades using both experimental and theoretical methods. In this paper, cracking susceptibility was investigated by a simulation method for three series of aluminum alloys: AA2xxx, AA6xxx, and AA7xxx alloys. The simulation tool was developed using the CALPHAD method and is readily applicable to multicomponent alloy systems. For each series of alloys, cracking susceptible index values were calculated for more than 1000 alloy compositions by high-throughput calculation. Cracking susceptible maps were then constructed for these three series of aluminum alloys using the simulated results. The effects of major and minor alloying elements were clearly demonstrated by these index maps. The cooling rate effect was also studied, and it was concluded that back diffusion in the solid can significantly improve the cracking susceptibility.

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9

Gao, Zhi Guo. "Numerical Analysis of Solidification Behavior during Laser Welding Nickel-Based Single-Crystal Superalloy Part: II Crystallography-Dependent Supersaturation of Liquid Aluminum." Materials Science Forum 1018 (January 2021): 13–22. http://dx.doi.org/10.4028/www.scientific.net/msf.1018.13.

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The thermal metallurgical modeling of liquid aluminum supersaturation was further developed through couple of heat transfer model, dendrite selection model, multicomponent dendrite growth model and nonequilibrium solidification model during three-dimensional nickel-based single-crystal superalloy weld pool solidification. The welding configuration plays more important role in supersaturation of liquid aluminum, morphology instability and nonequilibrium partition behavior. The bimodal distribution of liquid aluminum supersaturation along the solid/liquid interface is crystallographically symmetrical about the weld pool centerline in (001) and [100] welding configuration. The distribution of liquid aluminum supersaturation along the solid/liquid interface is crystallographically asymmetrical throughout the weld pool in (001) and [110] welding configuration. Optimum low heat input (low laser power and high welding speed) with (001) and [100] welding configuration is more favored to predominantly promote epitaxial [001] dendrite growth to reduce the metallurgical factors for solidification cracking than that of high heat input (high laser power and slow welding speed) with (001) and [110] welding configuration. The lower the heat input is used, the lower supersaturation of liquid aluminum is imposed, and the smaller size of vulnerable [100] dendrite growth region is incurred to ameliorate solidification cracking susceptibility and vice versa. The overall supersaturation of liquid aluminum in (001) and [100] welding configuration is beneficially smaller than that of (001) and [110] welding configuration regardless of heat input, and is not thermodynamically relieved by gamma prime γˊ phase. (001) and [110] welding configuration is detrimental to weldability and deteriorates the solidification cracking susceptibility because of unfavorable crystallographic orientations and alloying aluminum enrichment. The mechanism of asymmetrical solidification cracking because of crystallography-dependent supersaturation of liquid aluminum is proposed. The eligible solidification cracking location is particularly confined in [100] dendrite growth region. Moreover, the theoretical predictions agree well with the experiment results. The useful modeling is also applicable to other single-crystal superalloys with similar metallurgical properties for laser welding or laser cladding. The thorough numerical analyses facilitate the understanding of weld pool solidification behavior, microstructure development and solidification cracking phenomena in the primary γ phase, and thereby optimize the welding conditions (laser power, welding speed and welding configuration) for successful crack-free laser welding.

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10

Yang, Xiao, Yan Liu, Xian-feng Zhang, Xue-feng Li, Xin-yao Zhang, and Ling-qing Gao. "Characterization of hydrogen assisted corrosion cracking of a high strength aluminum alloy." Materials Testing 64, no. 10 (October 1, 2022): 1527–31. http://dx.doi.org/10.1515/mt-2022-0079.

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Abstract Environmentally and hydrogen assisted cracking can occur during application of high-strength aluminum alloys. However, there are only few suitable laboratory procedures to characterize and evaluate the environmentally and hydrogen assisted cracking behavior of materials. By optimizing the hydrogen charging parameters and slow strain rate, a multidimensional test procedure was established, which could simulate the actual working environment and could realize the test and evaluation of hydrogen assisted cracking susceptibility in the laboratory. Moreover, it provides a new environmental adaptability evaluation method for the high-strength aluminum alloy materials.

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11

Gao, Zhi Guo. "Numerical Analysis of Solidification Behavior during Laser Welding Nickel-Based Single-Crystal Superalloy Part I: Crystallography-Dependent Solid Aluminum Distribution." Materials Science Forum 1020 (February 2021): 13–22. http://dx.doi.org/10.4028/www.scientific.net/msf.1020.13.

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The thermal metallurgical modeling of alloying aluminum redistribution was further developed through couple of heat transfer model, dendrite selection model, multicomponent dendrtie grwoth model and nonequilibrium solidification model during three-dimensional nickel-based single-crystal superalloy weld pool solidification over a wide range of welding conditions (laser power, welding speed and welding configuration) to facilitate understanding of solidification cracking phenomena. It is indicated that the welding configuration plays more important role than heat input in aluminum redistribution. The bimodal distribution of solid aluminum concentration along the solid/liquid interface is crystallographically symmetrical about the weld pool centerline for (001) and [100] welding configuration, while the distribution of solid aluminum concentration along the solid/liquid interface is crystallographically asymmetrical throughout the weld pool for (001) and [110] welding configuration. The size of vulnerable [100] dendrite growth region is beneficially suppressed in favor of epitaxial [001] dendrite growth region through optimum low heat input (low laser power and high welding speed) to facilitate single-crystal dendrite growth for successful crack-free weld at the expense of shallow weld pool geometry. The overall aluminum concentration in (001) and [100] welding configuration is significantly smaller than that of (001) and [110] welding configuration regardless of heat input. Severe aluminum enrichment is confined to [100] dendrite growth region where is more susceptible to solidification cracking. Heat input and welding configuration are optimized in order to minimize the solidification cracking susceptibility and improve microstructure stability. The relationship between welding conditions and alloying aluminum redistribution are established for solidification cracking susceptibility evaluation. The higher heat input is used, the more aluminum enrichment is monotonically incurred by diffusion with considerable increase of metallurgical driving forces for morphology instability and microstructure anomalies to deteriorate weldability and vice versa. The mechanism of asymmetrical solidification cracking because of crystallography-dependent alloying redistribution is proposed. The theoretical predictions agree well with the experiment results. Moreover, the useful modeling is also applicable to other single-crystal superalloys with similar metallurgical properties during laser welding or laser cladding.

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12

Gao, Zhi Guo. "Numerical Analysis of Microstructure Anomalies during Laser Welding Nickel-Based Single-Crystal Superalloy Part III: Amelioration of Solidification Behavior." Materials Science Forum 1041 (August 4, 2021): 47–56. http://dx.doi.org/10.4028/www.scientific.net/msf.1041.47.

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The contribution of crystallography-dependent metallurgical factors, such as supersaturation of liquid aluminum and minimum dendrite tip undercooling, to solidification behavior and microstructure development is numerically analyzed during Ni-Cr-Al ternary single-crystal superalloy molten pool solidification to better understand thermodynamic and kinetic driving forces behind solidification cracking resistance. The variation of supersaturation of liquid aluminum and minimum dendrite tip undercooling with location of solid/liquid interface is symmetrically consistent in (001)/[100] welding configuration. By comparison, the variation is asymmetrically consistent in (001)/[110] welding configuration. The different distribution is attributed to growth crystallography and dendrite selection. Significant increase of supersaturation of liquid aluminum and dendrite tip undercooling from [010] dendrite growth region to [100] dendrite growth region preferentially aggravates microstructure development as result of nucleation and growth of stray grain formation with the same heat input on each half of the weld pool in (001)/[110] welding configuration. High heat input (both increasing laser power and decreasing welding speed) exacerbates supersaturation of liquid aluminum and dendrite tip undercooling by faster diffusion to incur stray grain formation with severity of contributing thermometallurgical factors for susceptibility to solidification cracking, while low heat input (both decreasing laser power and increasing welding speed) ameliorates microstructure development and increases resistance to solidification cracking. Weld microstructure of optimum welding conditions, such as combination of low heat input and (001)/[100] welding configuration, is less susceptible to solidification cracking to suppress asymmetrical microstructure development and improve weld integrity potential rather than insidious welding conditions, such as combination of high heat input and (001)/[110] welding configuration. Severer supersaturation of liquid aluminum and wider dendrite tip undercooling occur in the [100] dendrite region as consequence of alloying enrichment, while smaller supersaturation of liquid aluminum and narrower dendrite tip undercooling occur in the [001] dendrite region as consequence of alloying depletion to spontaneously facilitate epitaxial growth of single-crystal essential. Symmetrical (001)/[100] welding configuration decreases growth kinetics of dendrite tip with smaller overall supersaturation of liquid aluminum and dendrite tip undercooling than that of asymmetrical (001)/[110] welding configuration regardless of combination of laser power and welding speed. Mitigation of supersaturation of liquid aluminum and dendrite tip undercooling simultaneously alleviate crack-susceptible microstructure development and solidification cracking. Additionally, the appropriate mechanism of solidification cracking resistance improvement through modification of crystallography-dependent supersaturation and undercooling of dendrite tip is proposed. Calculation analyses are sufficiently explained by experiment results in a reasonable way. The additional purpose of this theoretical analysis is to evaluate solidification cracking susceptibility of similar nickel-based or iron-based single-crystal superalloys.

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13

Huang, An Guo, Hu Zhang, Jing Fu Liu, Wei Yu, Zhi Yuan Li, and Hao Li. "Study on Solidification Crack Criterion during Laser Welding Pure Aluminum and ZL114A Aluminum Alloy." Advanced Materials Research 308-310 (August 2011): 852–58. http://dx.doi.org/10.4028/www.scientific.net/amr.308-310.852.

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Laser welding of 1A90 pure aluminum and ZL114A aluminum alloy with powder under the same laser welding parameters were carried out in this work. The relation between weld elements and solidification cracking formation of these two materials was investigated in the perspective of metallurgical factor. And the alloy element contents and distribution near the cracks were determined by scanning electron microscope (SEM) and energy-dispersive X-ray spectroscopy (EDS). Then the concept of weld element equivalent was introduced comparing with the carbon equivalent expression. The weld element equivalent expressions were established by using mathematics regress. And the verified results indicate that the weld element equivalent expressions can properly forecast the formation of solidification cracking.

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14

Huang, M., Z. Suo, Q. Ma, and H. Fujimoto. "Thin Film Cracking and Ratcheting Caused by Temperature Cycling." Journal of Materials Research 15, no. 6 (June 2000): 1239–42. http://dx.doi.org/10.1557/jmr.2000.0177.

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Layered materials are susceptible to failure upon temperature cycling. This paper describes an intriguing mechanism: cracking in a brittle layer caused by ratcheting in an adjacent ductile layer. For example, on a silicon die directly attached to an organic substrate, cracking often occurs in the silicon nitride film over aluminum pads. The silicon die and the organic substrate have different thermal expansion coefficients, inducing shear stresses at the die corners. Aided by cycling temperature, the shear stresses cause ratcheting in the aluminum pads. Incrementally, the stress relaxes in the aluminum pads and builds up in the overlaying silicon nitride film, leading to cracks.

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15

Panagopoulos, C., Emmanuel Georgiou, K. Giannakopoulos, and P. Orfanos. "Effect of pH on Stress Corrosion Cracking of 6082 Al Alloy." Metals 8, no. 8 (July 26, 2018): 578. http://dx.doi.org/10.3390/met8080578.

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In this work, the effect of pH (3, 7 and 10) on the stress corrosion cracking behavior of 6082 aluminum alloy, in a 0.3 M sodium chloride (NaCl) aqueous based solution was investigated. The stress corrosion cracking behavior was studied with slow strain rate testing, whereas failure analysis of the fractured surfaces was used to identify the dominant degradation mechanisms. The experimental results clearly indicated that stress corrosion cracking behavior of this aluminum alloy strongly depends on the pH of the solution. In particular, the highest drop in ultimate tensile strength and ductility was observed for the alkaline pH, followed by the acidic, whereas the lowest susceptibility was observed in the neutral pH environment. This observation is attributed to a change in the dominant stress corrosion cracking mechanisms.

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16

Lee, Cheng Kuo, Chung Sheng Chang, An Hung Tan, Ching Yi Yang, and Sheng Long Lee. "Preparation of Electroless Nickel-Phosphorous-TiO₂ Composite Coating for Improvement of Wear and Stress Corrosion Cracking Resistance of AA7075 in 3.5% NaCl." Key Engineering Materials 656-657 (July 2015): 74–79. http://dx.doi.org/10.4028/www.scientific.net/kem.656-657.74.

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In this study nanoTiO2 particles were incorporated into the electroless plating solution to prepare Ni-P-TiO2 composite coating on anodized AA7075 aluminum alloy to improve the wear and stress corrosion cracking resistance of the coated alloy in 3.5%NaCl solution. The anodized AA7075 aluminum alloy was also performed by a boiling water sealing treatment for comparison. The wear and stress corrosion cracking (SCC) characteristics were investigated using a self-designed block-on-ring machine and slow strain rate test. The effect of corrosion was evaluated by electrochemical polarization measurements. The surface morphology, element composition and surface hardness of the coating were analyzed by scanning electron microscopy (SEM), X-ray energy dispersive spectrometry (EDS) and Vicker′s hardness tester. Experimental results indicated that after boiling water sealing treatment the resistance properties of the anodized AA7075 aluminum alloy were further improved. The anodizing treatment of AA7075 aluminum alloy gave a thick film with high porosity. The porous film efficiently improved the cohesion, adhesion and hardness of the electroless Ni-P composite coating. Therefore, the electroless Ni-P composite coating deposited on the anodized AA7075 aluminum alloy offered a superior wear, pitting corrosion and stress corrosion cracking resistance properties than both anodizing and sealing treatment. By comparison with Ni-P and Ni-P-TiO2 coatings the incorporation of TiO2 resulted in a more uniform and crack-free surface structure of the composite coating. This is responsible for the higher hardness, better wear, pitting corrosion and stress corrosion cracking resistance of the electroless Ni-P-TiO2 coating.

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17

Zhang, Fang Fang, Chun Feng, Li Juan Zhu, and Wen Wen Song. "Research Progress on Corrosion Resistance of Titanium Alloy Oil Well Tubing." Materials Science Forum 1035 (June 22, 2021): 528–33. http://dx.doi.org/10.4028/www.scientific.net/msf.1035.528.

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Compared with aluminum alloy and alloy steel, titanium alloy has higher specific strength, lower modulus of elasticity, and better toughness, fatigue performance and corrosion resistance. In terms of oil well tubing, the development of titanium alloy lags behind that of aluminum alloy and alloy steel. Aluminum alloy tubing is sensitive to pitting, fatigue corrosion and stress corrosion cracking. At the same time, it is not suitable for ultra-deep wells due to temperature limitations. Easily interact with corrosive media to cause corrosion and cracking. Titanium alloy oil well tubing is expected to solve this corrosion problem, but its corrosion resistance research is still incomplete. Therefore, it is necessary to develop titanium alloy oil well tubing with good corrosion resistance to improve corrosion fatigue (CF), fatigue during deep oil well and natural gas drilling operations. Catastrophic brittle fracture caused by hydrogen induced cracking (HIC), pitting corrosion and sulfide stress cracking (SSC). In this paper, by investigating a large number of domestic and foreign documents, the corrosion types of titanium alloy oil well pipes are analyzed, and the research status of corrosion resistance of titanium alloy oil well pipes is reviewed from three aspects: oil pipes, casings and drill pipes.

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18

Yu, Yan Yan, Ti Jie Song, and Zeng Wei Lu. "Law and Fracture Characteristics of Stress Corrosion Cracking for 7B04 Aluminum Alloy." Materials Science Forum 1032 (May 2021): 207–12. http://dx.doi.org/10.4028/www.scientific.net/msf.1032.207.

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Two states of aluminum alloy material 7B04 T651 and 7B04 T74 using C-ring specimen were selected to carry out stress corrosion simulation test with different stress levels, corrosion concentrations and time, and the fracture morphology of the crack was observed and analyzed by optical microscope and scanning electron microscope (SEM). The results showed that 7B04-T74 alloy was insensitive to stress corrosion and was not prone to stress corrosion cracking under constant tensile stress lower than 432MPa; The stress corrosion cracking time of 7B04 T651 alloy under three different concentrations has no significant difference, and the stress corrosion cracking occurs within 7 days under the stress of 180MPa-432MPa. The time of stress corrosion cracking increased with the decrease of stress. Stress corrosion cracking (SCC) was very sensitive to Cl element, and it was also easy to produce SCC when the concentration of corrosive medium was low, the threshold value of corrosion cracking was about 108 MPa. SEM and EDS analysis showed that the fracture surface was intergranular, mud-like corrosion products, and secondary cracks. At the same time, the matrix grain boundaries were weakened by Cl element.

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19

Wheeler, D. A., and R. G. Hoagland. "Observations of cracking behavior and non-unique cracking thresholds during LME of aluminum." Scripta Metallurgica 20, no. 10 (October 1986): 1433–38. http://dx.doi.org/10.1016/0036-9748(86)90110-9.

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20

Shen, L., H. Chen, L. D. Xu, X. L. Che, and Y. Chen. "Stress corrosion cracking and corrosion fatigue cracking behavior of A7N01P-T4 aluminum alloy." Materials and Corrosion 69, no. 2 (August 31, 2017): 207–14. http://dx.doi.org/10.1002/maco.201709527.

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21

Volkova, L. D., N. N. Zakarina, O. K. Kim, A. K. Akurpekova, D. A. Zhumadullaev, V. I. Yaskevich, V. P. Grigorjeva, and A. V. Gabdrakipov. "KAOLINITE MODIFIED BY ALUMINUM IN THE CRACKING OF VACUUM GASOIL AND IT’S MIXTURE WITH FUEL OIL." SERIES CHEMISTRY AND TECHNOLOGY 2, no. 440 (April 15, 2020): 107–14. http://dx.doi.org/10.32014/2020.2518-1491.30.

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The data of the cracking of vacuum gas oil (VG) and a mixture of VG with fuel oil (M-100) on HLaY zeolite catalyst based on acid-activated kaolinite of the Pavlodar deposit modified by aluminum are presented. The synthesis of the kaolinite matrix and the HLaY zeolite catalyst with its use, the physicochemical and acid characteristics of the catalyst and its constituent components, and the fractional and hydrocarbon compositions of vacuum gas oil are described. High mesoporosity of the H-form of the used kaolinite (86.2%), modified by aluminum of the H-form (84.1) and the HLaY catalyst (80.1%), which provide the activity of the sample in cracking of the mixture with a yield of 32.6% gasoline and 25.9% light gas oil (LG) at 4500С and in cracking of VG a yield of 38.2% gasoline and 29.4% LG at 5000С. The gasolines of cracking of LG contain an increased content of iso paraffins (up to 20.2%) and a low content of aromatic hydrocarbons (24.1%), which makes the catalyst attractive for cracking a mixture of VG with fuel oil. Key words: catalytic cracking, kaolinite, vacuum gas oil, fuel oil, zeolite, modification.

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22

Y, Tilahun, and Mesfin G. "A Review on Role of Aluminum Matrix Materials, Failure Causes and Optimization Techniques." International Innovative Research Journal of Engineering and Technology 6, no. 3 (March 31, 2021): 1–11. http://dx.doi.org/10.32595/iirjet.org/v6i3.2021.143.

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Aluminum is a metal matrix material which is widely used in different industrial as well as engineering applications.it has a great advantage due to its remarkable properties like less density, formability, and light in weight, recyclability and other properties. but, failure of aluminum matrix materials are the main problems in aluminum industries now a days.in this review role of aluminum and its alloys as matrix materials, their failure modes, causes of failure and optimization techniques to minimize this failure modes and causes of failure are discussed. Sources are reviewed which are from 2005 to recent one. Consequently, most modes of failure, causes of failure and most optimization techniques of aluminum and its alloy matrix materials are found. most modes of failure are mechanical related like fatigue failure, surface cracking, ductile failure, porosity formation, and stress related like stress corrosion cracking, surface weakness due to repeated stresses and other factors are summarized.in causes of failure mostly like corrosion formation, wear formation and poor mechanical properties are discussed.

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23

Y, Tilahun, and Mesfin G. "A Review on Role of Aluminum Matrix Materials, Failure Causes and Optimization Techniques." International Innovative Research Journal of Engineering and Technology 6, no. 3 (March 31, 2021): 1–11. http://dx.doi.org/10.32595/iirjet.org/v6i.2021.143.

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Aluminum is a metal matrix material which is widely used in different industrial as well as engineering applications.it has a great advantage due to its remarkable properties like less density, formability, and light in weight, recyclability and other properties. but, failure of aluminum matrix materials are the main problems in aluminum industries now a days.in this review role of aluminum and its alloys as matrix materials, their failure modes, causes of failure and optimization techniques to minimize this failure modes and causes of failure are discussed. Sources are reviewed which are from 2005 to recent one. Consequently, most modes of failure, causes of failure and most optimization techniques of aluminum and its alloy matrix materials are found. most modes of failure are mechanical related like fatigue failure, surface cracking, ductile failure, porosity formation, and stress related like stress corrosion cracking, surface weakness due to repeated stresses and other factors are summarized.in causes of failure mostly like corrosion formation, wear formation and poor mechanical properties are discussed.

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24

Pan, Wei, Ziyu Zhai, Yantao Liu, Bo Liang, Zhuoheng Liang, and Yongzhong Zhang. "Research on Microstructure and Cracking Behavior of Al-6.2Zn-2Mg-xSc-xZr Alloy Fabricated by Selective Laser Melting." Crystals 12, no. 10 (October 21, 2022): 1500. http://dx.doi.org/10.3390/cryst12101500.

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Selective laser melting (SLM) offers obvious advantages in the production of complex parts. However, the traditional 7xxx series aluminum alloy has a serious cracking tendency in the SLM process. Therefore, in order to analyze the microstructure and cracking mechanism, and obtain crack-free aluminum alloy fabricated by SLM, this paper studied the microstructure characteristics of as-deposited Al-6.2Zn-2Mg-xSc-xZr alloy with different Sc, Zr content, as well as the influence mechanism of Sc, Zr on cracking. The results show that with the increase of Sc and Zr content, the crack tendency and grain size decrease. When Sc and Zr content reach 0.6% and 0.36% respectively, cracks can no longer be observed in the as deposited alloy. The microstructure of the as deposited Al-6.2Zn-2Mg-0.6Sc-0.36Zr alloy consists of fine equiaxed and columnar crystals, in which Sc and Zr mainly exist in the aluminum matrix as solid solutions, and some exist in the form of Al3(Sc, Zr). The immediate reason for the absence of cracks is that the microstructure changes from coarse columnar grains to fine equiaxed-columnar grains when the content of Sc and Zr increases. The refined grain size may have the following beneficial effects: It helps with reducing the thickness of the liquid films. This will increase the tear sensitivity of the liquid film and the cracking tendency and therefore lowers the hot cracking tendency; And a refined grain size improves fracture roughness, leading to an enhanced cracking resistance. At the same time, the refinement of the grains will make the feeding channel of the grain boundary shorter and easy to feed, and the fine equiaxed grains can coordinate stress-strain during solidification more effectively than coarse columnar grains, which will decrease the cracking tendency.

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25

OHNISHI, Tadakazu, Hiroyuki KOJIMA, Nobuya SEKO, and Kenji HIGASHI. "Stress corrosion cracking of 7075 series aluminum alloys." Journal of Japan Institute of Light Metals 35, no. 6 (1985): 344–52. http://dx.doi.org/10.2464/jilm.35.344.

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26

Abbaschian, Lara, and Milton Sergio Fernandes de Lima. "Cracking susceptibility of aluminum alloys during laser welding." Materials Research 6, no. 2 (June 2003): 273–78. http://dx.doi.org/10.1590/s1516-14392003000200024.

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27

Balasubramaniam, R., D. J. Duquette, and K. Rajan. "On stress corrosion cracking in aluminum-lithium alloys." Acta Metallurgica et Materialia 39, no. 11 (November 1991): 2597–605. http://dx.doi.org/10.1016/0956-7151(91)90075-c.

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28

Zielinski, A. "Hydrogen-enhanced stress-corrosion cracking of aluminum alloys." Materials Science 34, no. 4 (July 1998): 469–75. http://dx.doi.org/10.1007/bf02360698.

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29

Qi, Ting, Haihong Zhu, Xiaoyan Zeng, and Jie Yin. "Effect of Si content on the cracking behavior of selective laser melted Al7050." Rapid Prototyping Journal 25, no. 10 (November 11, 2019): 1592–600. http://dx.doi.org/10.1108/rpj-12-2018-0310.

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Анотація:

Purpose It is a crucial issue to eliminate cracks for selective laser melting (SLM) 7xxx series aluminum alloy. This paper aims to study the effect of silicon content on the cracking behavior and the mechanism of eliminating crack of SLMed Al7050 alloy. Design/methodology/approach Six different silicon contents were added to the Al7050 powder. The crack density and crack count measuring from optical micrographs were utilized to judge the cracking susceptibility. The low melting phases analyzing from Jmatpro and the microstructure observing by EPMA and SEM were used to discuss the mechanism of eliminating the crack. Findings The cracking susceptibility of SLMed Al7050 alloy decreases with the increase of adding silicon content. When adding silicon, two new low-melting phases appeared: Mg2Si and Al5Cu2Mg8Si6. These low-melting phases offer much liquid feeding along the grain boundary and decrease the cracking susceptibility. Moreover, the grains are obviously refined after adding silicon. The fine grain can increase the total surface area of the grain boundary, which can reinforce the matrix and decrease the cracking susceptibility. High silicon content results in more low-melting phases and fine grains, which decreases the cracking susceptibility. Originality/value The investigation results can help to obtain crack-free SLMed Al7050 parts and deep knowledge on eliminating cracking mechanism of high-strength aluminum alloy fabricated by SLM.

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30

Nishijima, Dai, Tatsuo Tabaru, and Morito Akiyama. "Cracking of Aluminum Nitride Film on Stainless Steel Substrate at Elevated Temperature." Materials Science Forum 561-565 (October 2007): 1221–24. http://dx.doi.org/10.4028/www.scientific.net/msf.561-565.1221.

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Aluminum nitride (AlN) thin films formed on the heat-resistant alloy substrates were heated to 1100K. Cracking was observed in the AlN film formed on the stainless steel substrate (SUS430), while no crack was seen in that on the nickel-base superalloy substrate (IN750X). The electrical impedance measurements, X-ray diffraction analysis and finite element method calculation have been conducted to discuss the relationship between the cracking and the stress introduced into the AlN films. The AlN film cracking would be significantly affected by grain refinement of AlN.

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31

Li, Zhuoxin, Yulin Zhang, Hong Li, Yipeng Wang, Lijuan Wang, and Yu Zhang. "Liquation Cracking Susceptibility and Mechanical Properties of 7075 Aluminum Alloy GTAW Joints." Materials 15, no. 10 (May 20, 2022): 3651. http://dx.doi.org/10.3390/ma15103651.

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In this work, aluminum alloy 7075-T651 was welded by using customized Al-Cu-Si and Al-Cu-Mg-Zn filler wire during gas tungsten arc welding. The liquation cracking susceptibility of the joints was tested under a circular-patch welding experiment. Besides, the temperature vs. solid fraction curves (T-fS) was calculated for different samples to reveal the formation mechanism of liquation cracking. The joint was susceptible to liquation cracking if (fS)weld > (fS)workpiece during the cooling stage. The results of the circular-patch welding experiment show that the liquation cracking susceptibility of the joint by using ER5356, Al-Cu1.5-Si4.5, Al-Cu3.0-Si2.5, Al-Cu4.5-Si1.5, Al-Cu2.3-Mg2.3-Zn6.6 and Al-Cu2.2-Mg2.0-Zn7.8 filler metal is 22.8%, 8.3%, 2.8%, 2.8%, 3.3% and 1.4%, respectively. The mechanical test shows that the data dispersion of the 7075 gas tungsten arc welding joint can be decreased by eliminating the liquation crack.

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32

Manaka, Toshiaki, Masaya Aoki, and Goroh Itoh. "Thermal Desorption Spectroscopy Study on the Hydrogen Behavior in a Plasma-Charged Aluminum." Materials Science Forum 879 (November 2016): 1220–25. http://dx.doi.org/10.4028/www.scientific.net/msf.879.1220.

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Hydrogen in aluminum has been known to be the cause of blister and pore. Some aluminum alloy is susceptible to stress corrosion cracking, which is based on intergranular cracking arisen from hydrogen embrittlement. The behavior of hydrogen in aluminum has not been fully understood yet. Hydrogen gas plasma enables to introduce high hydrogen concentrations into specimen without Al (OH)3 layer on the surface of specimen. In this paper, we have investigated the behavior of hydrogen in a plasma charged aluminum by means of thermal desorption spectroscopy, a method to evaluate the amount and trap states of hydrogen. Cold-rolled pure aluminum were annealed, electro-polished and charged with hydrogen gas plasma. Immediately after hydrogen gas plasma charging, TDS tests were performed under ultra-high vacuum. The hydrogen desorption spectrums obtained by TDS tests had three peaks corresponding to the co-diffusion of hydrogen-vacancy pair, dislocation and pore. Compared to a sample without charging, in a plasma charged sample, the amount of hydrogen trapped in vacancies especially increased.

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33

Ostapiuk, Monika, Jarosław Bieniaś, and Barbara Surowska. "Analysis of the bending and failure of fiber metal laminates based on glass and carbon fibers." Science and Engineering of Composite Materials 25, no. 6 (November 27, 2018): 1095–106. http://dx.doi.org/10.1515/secm-2017-0180.

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AbstractThe purpose of this paper is to investigate the mechanisms of cracking and failure in fiber metal laminates (FMLs) subjected to 3-point bending. Two types of laminates, based on the glass/epoxy and carbon/epoxy composites, were selected for the study. The paper presents the failures of matrix and fibers as well as the effects of different thicknesses of metal layers on the tested laminates. The mechanisms of failure observed for the two tested types of fibers with uniform thickness of aluminum sheets seem similar. The results demonstrate that the tested laminates exhibit the following failure modes: fiber breakage, matrix cracking, fiber/matrix debonding, delamination, and anodic layer failure. Given the behavior of aluminum under the compressive and tensile stresses, the aluminum layer acts as a barrier preventing FML failure during bending. In addition to aluminum layer thickness, the fiber type and composite layer directions are also important factors to be considered.

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34

Rusnak, Cameron R., and Craig C. Menzemer. "Fatigue Behavior of Nonreinforced Hand-Holes in Aluminum Light Poles." Metals 11, no. 8 (July 30, 2021): 1222. http://dx.doi.org/10.3390/met11081222.

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Hand-holes are present within the body of welded aluminum light poles. They are used to provide access to the electrical wiring for both installation and maintenance purposes. Wind is the main loading on these slender aluminum light poles and acts in a very cyclic way. In the field, localized fatigue cracking has been observed. This includes areas around hand-holes, most of which are reinforced with a cast insert welded to the pole. This study is focused on an alternative design, specifically hand-holes without reinforcement. Nine poles with 18 openings were fatigue tested in four-point bending at various stress ranges. Among the 18 hand-holes tested, 17 failed in one way or another as a result of fatigue cracking. Typically, fatigue cracking would occur at either the 3:00 or 9:00 positions around the hand-hole and then proceed to propagate transversely into the pole before failure. Finite element analysis was used to complement the experimental study. Models were created with varying aspect ratios to see if the hand-hole geometry had an effect on fatigue life.

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35

Burapa, R., S. Rawangwong, J. Chatthong, and Worapong Boonchouytan. "Effects of Mold Temperature and Casting Temperature on Hot Cracking in Al-4.5 wt.% Cu Alloy." Advanced Materials Research 747 (August 2013): 623–26. http://dx.doi.org/10.4028/www.scientific.net/amr.747.623.

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Hot cracking is an important defect that occurs during solidification of aluminum-copper alloys. In this present work, the effects of mold temperature and casting temperature on hot cracking in the Al-4.5 wt.% Cu alloy has been studied using a ring mold for hot cracking assessment. For the experimental conditions, three mold temperatures between 150 and 350°C and three casting temperatures between 670 and 770°C were studied and Al-7 wt.% Si alloy was used as reference for comparison. The results showed Al-7 wt.% Si alloy has high resistance to hot cracking and no hot cracking forms under three different mold temperatures, while Al-4.5 wt.% Cu alloy shows significant hot cracking tendency under the same casting conditions. The severity of hot cracking in Al-4.5 wt.% Cu alloy decreased significantly with increasing the mold temperature and decreasing the casting temperature. On the other hand, an increasing casting temperature resulted in severer hot cracking in Al-4.5 wt.% Cu alloy.

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36

Grant Norton, M., Jacek M. Kajda, and Brian C. H. Steele. "Brazing of aluminum nitride substrates." Journal of Materials Research 5, no. 10 (October 1990): 2172–76. http://dx.doi.org/10.1557/jmr.1990.2172.

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Aluminum nitride (AlN) is currently under investigation as a potential candidate for replacing aluminum oxide (Al2O3) as a substrate material for electronic circuit packaging. The requirements for such a material are that it can be metallized and joined to produce hermetic enclosures for semiconductor devices. A technique for brazing AlN using a nonactive metal braze has been investigated. The process involves the in situ decomposition of an active metal hydride. This process improves the wetting of the AlN and led to the development of strong bonding between braze and ceramic. The ceramic-braze interface was studied using scanning electron microscopy (SEM). The nature of the interfacial reactions and the reaction products have been identified using x-ray diffraction (XRD). The progress of the reaction has been followed using differential thermal analysis (DTA). The experimental results have been correlated with thermodynamic predictions of the reaction processes. In addition to joining ceramic to ceramic, braze joints of AlN to copper and to a low expansion iron-nickel lead frame alloy were made. Residual stress resulting from a mismatch of thermal expansion coefficients between AlN and copper caused cracking in the ceramic upon cooldown from the brazing temperature. No cracking occurred in the ceramic when joined to the iron-nickel alloy. The results obtained are important for the realization of AlN as a ceramic packaging material for semiconductor devices.

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37

Lalpoor, Mehdi, Dmitry G. Eskin, Hallvard Gustav Fjær, Andreas Ten Cate, Nick Ontijt, and Laurens Katgerman. "Application of a Criterion for Cold Cracking to Casting High Strength Aluminium Alloys." Materials Science Forum 654-656 (June 2010): 1432–35. http://dx.doi.org/10.4028/www.scientific.net/msf.654-656.1432.

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Direct chill (DC) casting of high strength 7xxx series aluminum alloys is difficult mainly due to solidification cracking (hot cracks) and solid state cracking (cold cracks). Poor thermal properties along with extreme brittleness in the as-cast condition make DC-casting of such alloys a challenging process. Therefore, a criterion that can predict the catastrophic failure and cold cracking of the ingots would be highly beneficial to the aluminum industry. The already established criteria are dealing with the maximum principal stress component in the ingot and the plane strain fracture toughness (KIc) of the alloy under discussion. In this research work such a criterion was applied to a typical 7xxx series alloy which is highly prone to cold cracking. The mechanical properties, constitutive parameters, as well as the KIc values of the alloy were determined experimentally in the genuine as-cast condition and used as input data for the finite element package ALSIM5. Thermomechanical simulations were run for billets of various diameters and the state of residual thermal stresses was determined. Following the contour maps of the critical crack size gained from the model, the casting conditions were optimized to produce a crack-free billet.

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38

TAKAHASHI, Akihiro, Toshiro KOBAYASHI, and Hiroyuki TODA. "Stress criterion of delamination cracking in 2091 aluminum alloys." Journal of Japan Institute of Light Metals 49, no. 6 (1999): 249–52. http://dx.doi.org/10.2464/jilm.49.249.

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39

OHNISHI, Tadakazu, Takeshi HAMAMOTO, Harushige TSUBAKINO, and Yuji TANIBUCHI. "Stress corrosion cracking of RRA-treated 7050 aluminum alloy." Journal of Japan Institute of Light Metals 43, no. 6 (1993): 308–13. http://dx.doi.org/10.2464/jilm.43.308.

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40

Tsai, T. C., J. C. Chang, and T. H. Chuang. "Stress corrosion cracking of superplastically formed 7475 aluminum alloy." Metallurgical and Materials Transactions A 28, no. 10 (October 1997): 2113–21. http://dx.doi.org/10.1007/s11661-997-0168-5.

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41

Yeoh, A., G. Prabhu, and C. Persad. "Liquation cracking and its effects in aluminum alloy armatures." IEEE Transactions on Magnetics 33, no. 1 (1997): 419–25. http://dx.doi.org/10.1109/20.560049.

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42

Bhuyan, G. S., and D. H. Carter. "Sustained-load-cracking characteristics of aluminum-lined NGV cylinders." International Journal of Pressure Vessels and Piping 60, no. 2 (1994): 183–92. http://dx.doi.org/10.1016/0308-0161(94)90025-6.

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43

Makar, G. L., J. Kruger, and K. Sieradzki. "Stress corrosion cracking of rapidly solidified magnesium-aluminum alloys." Corrosion Science 34, no. 8 (August 1993): 1311–42. http://dx.doi.org/10.1016/0010-938x(93)90090-4.

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44

Kim, Hwan Tae, and Soo Woo Nam. "Solidification cracking susceptibility of high strength aluminum alloy weldment." Scripta Materialia 34, no. 7 (April 1996): 1139–45. http://dx.doi.org/10.1016/1359-6462(95)00644-3.

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45

Shaw, W. J. D. "Stress corrosion cracking behavior of IN-9021 aluminum alloy." Metallography 19, no. 2 (May 1986): 227–33. http://dx.doi.org/10.1016/0026-0800(86)90038-8.

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46

Olik, A. P. "Cyclic cracking resistance of ship hull plate aluminum alloys." Soviet Materials Science 26, no. 4 (1991): 431–34. http://dx.doi.org/10.1007/bf00727058.

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47

Liu, Jiangwei, and Sindo Kou. "Susceptibility of ternary aluminum alloys to cracking during solidification." Acta Materialia 125 (February 2017): 513–23. http://dx.doi.org/10.1016/j.actamat.2016.12.028.

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48

Czechowski, M. "Stress corrosion cracking of explosion welded steel-aluminum joints." Materials and Corrosion 55, no. 6 (June 2004): 464–67. http://dx.doi.org/10.1002/maco.200303771.

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49

Cross, Carl E. "Applying Solidification Theory to Aluminum Weldability and Consumable Development." Welding Journal 101, no. 8 (August 1, 2022): 209–23. http://dx.doi.org/10.29391/2022.101.016.

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One defect encountered in the fusion zone when welding aluminum alloys involves solidification cracking (i.e., the tearing apart of grain boundary liquid films at the trailing edge of the weld pool). This problem can often be mitigated by the proper selection of filler metal. Two key engineering examples, one aerospace and one maritime, where this has occurred were examined in terms of alloy development to achieve optimum mechanical properties while maintaining weldability. Specifically, base metal/filler metal systems susceptible to cracking were examined in terms of filler metal dilution. A mechanism for crack growth was presented based upon critical strain rate. Conditions needed for improved weldability through grain refinement were defined based upon the columnar-to-equiaxed solidification theory.

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50

Xue, Xiao Huai, Hua Du, Hai Liang Yu, Shu Fang Yang, Zheng Cai Deng, and Song Nian Lou. "Cracking Susceptibility and Joint Property Study of the 6061 Aluminum." Materials Science Forum 546-549 (May 2007): 911–16. http://dx.doi.org/10.4028/www.scientific.net/msf.546-549.911.

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By means of FISICO test, the cracking susceptibility of the 6061 aluminum was investigated, the experimental results showed that it is prone to form crater crack under restraint condition comparison with that of the 3003 aluminum. So the crater fill-up technology need to be employed accordingly during the field welding. The strength, elongation percentage and hardness of the as welded joint was lowered 29.7%40%42% respectively, the former two is recovered to 73.4% and 81.7% of the base material respectively after natural aging 30days. This indicate that the natural aging treatment can remedy part of the property loss during the welding.

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