Aluminum welding filler metal, casting and wrought metal alloy

Abstract

A composition for producing aluminum casting, wrought, and welding filler metal alloys having a chemistry comprising Si varying from approximately 0.1 and 0.9 wt %,Mn varying from approximately 0.05 to 1.2 wt %, Mg varying from approximately 2.0 to 7.0 wt %, Cr varying from approximately 0.05 to 0.30 wt %, Zr varying from approximately 0.05 to 0.30 wt %, Ti varying from approximately 0.003 to 0.20 wt %, and B varying from approximately 0.0010 to 0.030 wt %, and a remainder of aluminum and various trace elements. The alloy is particularly suited to producing high strength structures such as automobiles, truck trailers, rail cars, and ships. It is the first 6 xxx series weld filler metal that can be post-weld thermally treated and can weld 3 xxx, 5 xxx, 6 xxx, and 7 xxx series base alloys yielding far superior mechanical properties than those attainable from any other aluminum filler metal.

What is claimed is: 
     
         1 . A composition for producing aluminum casting, wrought, and filler metal alloys from the same chemistry having a composition comprising silicon in a weight percentage of between approximately 0.01% inclusive and 0.9% inclusive; manganese in a weight percentage of between approximately 0.05% inclusive and 1.2% inclusive; magnesium in a weight percentage of between approximately 2.0% inclusive and 7.0% inclusive; chromium in a weight percentage of between approximately 0.05% inclusive and 0.30% inclusive; zirconium in a weight percentage of between approximately 0.05% inclusive and 0.30% inclusive; titanium in a weight percentage of between approximately 0.003% inclusive and 0.20% inclusive; and boron in a weight percentage of between approximately 0.0010% inclusive and 0.030% inclusive. 
     
     
         2 . In accordance with  claim 1 , a composition comprising silicon in a weight percentage of between approximately 0.50% inclusive and 0.70% inclusive; manganese in a weight percentage of between approximately 0.05% inclusive and 0.20% inclusive; magnesium in a weight percentage of between approximately 5.7% inclusive and 6.1% inclusive; chromium in a weight percentage of between approximately 0.05% inclusive and 0.20% inclusive; zirconium in a weight percentage of between approximately 0.05% inclusive and 0.15% inclusive; titanium in a weight percentage of between approximately 0.003% inclusive and 0.10% inclusive; and boron in a weight percentage of between approximately 0.0010% inclusive and 0.010% inclusive. 
     
     
         3 . In accordance with  claim 1 , a composition comprising silicon in a weight percentage of between approximately 0.30% inclusive and 0.50% inclusive; manganese in a weight percentage of between approximately 0.50% inclusive and 1.0% inclusive; magnesium in a weight percentage of between approximately 3.4% inclusive and 3.7% inclusive; chromium in a weight percentage of between approximately 0.05% inclusive and 0.20% inclusive; zirconium in a weight percentage of between approximately 0.05% inclusive and 0.15% inclusive; titanium in a weight percentage of between approximately 0.003% inclusive and 0.10% inclusive; and boron in a weight percentage of between approximately 0.0010% inclusive and 0.010% inclusive. 
     
     
         4 . In accordance with  claim 1 , a 6xxx series aluminum alloy composition that provides for the use of a single chemistry to produce castings, weld filler metals, and wrought base metal alloys that can be welded together into structures that will have closely matched mechanical and physical properties throughout resulting in welded structures that have mechanical properties substantially higher than anything achievable with the currently available aluminum alloys. 
     
     
         5 . In accordance with  claim 3 , a 6xxx series aluminum alloy filler metal composition that will respond to post-weld thermal treatments thereby allowing the restoration of mechanical properties degraded in the heat affected zone of heat treated alloys during welding operations thus yielding finished weldments where the resulting weld joint yields mechanical properties that meet or exceed that of both cast and wrought aluminum alloy components. 
     
     
         6 . In accordance with  claim 2 , a 6xxx series aluminum filler metal alloy composition capable of welding 3xxx, 5xxx, 6xxx, and 7xxx series aluminum metal alloys yielding higher mechanical properties and fatigue strength than can be achieved with any 4xxx or 5xxx series aluminum filler metal alloys currently available. 
     
     
         7 . In accordance with  claim 3 , a 6xxx series aluminum filler metal alloy composition capable of welding silicon based aluminum casting alloys to wrought 5xxx and 6xxx series aluminum alloys containing less than 3% Mg, yielding significantly higher mechanical properties than can be achieved with the 4xxx or 5xxx series aluminum filler metal alloys currently available. 
     
     
         8 . In accordance with  claim 3 , a 6xxx series aluminum filler metal alloy composition capable of being post-weld aged or post-weld heat treated and aged with mechanical properties in the as-welded or post-weld thermally treated condition that substantially exceed the post-welded properties of all of the currently available 4xxx and 5xxx series aluminum filler metal alloys while maintaining a high level of toughness. 
     
     
         9 . In accordance with  claim 3 , a 6xxx series aluminum filler metal alloy that can be used for elevated temperature applications up to 250 deg. F with higher mechanical properties than any other suitable filler metal alloy designed for elevated temperature applications that is currently available. 
     
     
         10 . In accordance with  claim 1 , a 6xxx series aluminum filler metal alloy composition that can be adjusted to provide color matching for post-weld anodizing treatments of various welded aluminum alloy components. 
     
     
         11 . In accordance with  claim 1 , a 6xxx series aluminum filler metal alloy composition that can be adjusted to provide corrosion protection properties that match or exceed those of the aluminum alloy components being welded. 
     
     
         12 . In accordance with  claim 1 , a 6xxx series aluminum filler metal alloy composition that will provide a typical electrical conductivity of approximately 23 IACS which will allow this alloy to be arc welded in the globular transfer or short arc mode which is not now possible with any other aluminum filler metal currently available. 
     
     
         13 . In accordance with  claim 11 , a 6xxx series aluminum filler metal alloy composition that creates higher resistance heating of the electrode during arc welding, resulting in reduced thermal energy required in the arc plasma which in turn produces a more stable droplet transfer with reduced Mg burn off and less undesirable condensation of vaporized Mg (referred to as smut) on the base metal surfaces resulting in lower shielding gas requirements and reduced welding costs. 
     
     
         14 . In accordance with  claim 11 , a 6xxx series aluminum filler metal alloy composition that increases melt-off rate of the electrode during arc welding and consequently a reduction of total heat input resulting in a reduction of the loss of mechanical properties in the heat affected zone and less mechanical distortion of aluminum base metal components being welded. 
     
     
         15 . In accordance with  claim 11 , a 6xxx series aluminum filler metal alloy composition that increases melt-off rate of the electrode during arc welding resulting in higher welding speeds and lower electrode consumption which reduces welding costs. 
     
     
         16 . In accordance with  claim 6 , a 6xxx series aluminum filler metal alloy composition that because of increased tensile strength, shear strength, and fracture toughness, provides the opportunity to reduce weld bead size and increase welding speeds resulting in cost savings in welding operations. 
     
     
         17 . In accordance with  claim 1 , a 6xxx series aluminum welding filler metal alloy composition that has lower molten surface tension than any 5xxx series filler metal alloy thus producing lower and flatter weld beads thereby improving the fatigue strength of the welded joint. 
     
     
         18 . In accordance with  claim 1 , a 6xxx series aluminum filler metal alloy that has higher molten fluidity than any current 5xxx series filler metal alloy thus increasing wettability during welding which improves fusion and flattens the edge of the weld bead thereby improving fatigue strength of the welded joint. 
     
     
         19 . In accordance with  claim 1 , a 6xxx series aluminum welding filler metal alloy that has a lower liquid solubility for hydrogen than any 5xxx series filler metal alloy, thus reducing the volume of hydrogen porosity present in solidified welded joints. 
     
     
         20 . In accordance with  claim 1 , a 6xxx series wrought aluminum alloy for use in producing forged and cold headed products such as rivets, and similar products which can be cold formed, then solution heat treated, quenched and aged to yield substantially higher mechanical properties along with the desired physical properties of corrosion resistance and anodized color matching.