welding aluminum 5052-h32 to 6061-t6

[winpop123]

We have a design whereby a bent peice of sheet meatal (5052-H32) will be welded to some structural angle(6061).

I don't see where there should be any problem with this. Can anyone confirm this or show me the error of my ways.

Application will be for mounting hardware for securing electronics inside a military vehicle.

Thanks

 

[CoryPad]

What process do you intend to use? GMAW, GTAW, other?

The ASM Handbook lists 6 different filler alloys (4043, 5183, 5356, 5554, 5556, & 5654) that could be used for the combination of 5052 & 6061. Each has its advantages and disadvantages, but none perfectly suited for the task. Are you willing to forgo some performance in corrosion, temperature resistance, ductility, strength, or ease of welding?

Regards,

Cory

Please see FAQ731-376 for tips on how to make the best use of Eng-Tips Fora.

 

[metengr]

Some additional reading and information

http://www.alcotec.com/default.html

 

[drawoh]

winpop123,

Aluminium 6061-T6 is heat treated to achieve its specified strength. Its annealed strength is around 8ksi. I have a very old handbook here that shows its welded yield strength at around 20ksi with Aluminium 4043 or 5356 filler. I would assume that this is achieved by heat treatment.

My handbook quotes 14ksi for annealed 5052, using 5356 filler. I no idea what happens when you solution heat treat and artificially age (T6) aluminium 5052.

If strength matters to you, you should consider screws, or using all the same material, preferably 5083. If you are determined to weld multiple materials, you should chat with your alumimium supplier and your fabricator.

If you have 6061-T6 extrusions welded and loaded in bending at the corners, large gussets can move those weak aluminium welds out to a position with better leverage.

JHG

 

[metengr]

drawoh;
The 5XXX series (5052) aluminum alloys are not heat treatable. The only consequence of heat from welding is softening of the original cold worked aluminium alloy.

 

[Heckler]

What about using rivets to fasten the sheetmetal to the structural components. If this is an equipment tray for the military I would consider making it from 2024 verses 5052 then use mechanical fasteners to mount the tray. I realize 2024 is harder to work with but it can be done providing the part has no tight bends or seams.

Best Regards,

Heckler
Sr. Mechanical Engineer
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