aluminium in commercial vehicles - European Aluminium Association

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124 EUROPEAN ALUMINIUM ASSOCIATION ALUMINIUM IN COMMERCIAL VEHICLES CHAPTER VIII 10.3. Weld defects & approval criteria Weld defects and quality levels are given in EN ISO 10042. Guidance for choice of quality level is given in EN 1090-3. An international nomenclature of defects has been established and is given in EN ISO 6520-1 which lists 6 groups of imperfections: • Group 100: Cracks • Group 200: Cavities and wormholes • Group 300: Solid inclusions TABLE VIII.4 LISTS SOME COMMON WELD DEFECTS AND THEIR CAUSES • Group 400: Lack of fusion and penetration • Group 500: Defects of shape • Group 600: Sundry defects N° Type of Defect Likely Cause Photos of Imperfections 101 Cracks Base alloy unsuitable Poor choice of filler metal Incorrect welding sequence Excessive clamping Sudden cooling 104 Crater cracks Pass finished with sudden arc cutoff 2012 Irregular wormholes Work inadequately degreased Work and/or filler wire dirty or wet Insufficient protection by inert gas (low gas flow or leak in the system) Pass begun on cold component High arc voltage Weld cooled too quickly 2014 Aligned wormholes Incomplete penetration (double pass) Temperature gradient between backing and work too abrupt Excessive gap between edges of the joint 300 Solid inclusions Dirty metal (oxides, brush hairs) 303 Oxide inclusions Poor gas shielding Metal stored in poor conditions Castings Defect 101 Defect 104 Defect 2012
EUROPEAN ALUMINIUM ASSOCIATION ALUMINIUM IN COMMERCIAL VEHICLES CHAPTER VIII 125 N° Type of Defect Likely Cause Photos of Imperfections 3041 Tungsten inclusions Electrode diameter too small (TIG) Poor handling by welder Excessive current density Poor quality of tungsten electrode 402 Incomplete penetration Inadequate cleaning (presence of oxide) Incorrect bevel preparation on thick work (too tight, excessive shoulder) Gap between workpieces too small (or incon-sistent) Low current, especially at the start of the seam Welding speed too fast High arc voltage 4011 Lack of fusion High arc voltage on edges Low current, especially at the start of the seam Work cold (difference in thickness between materials to be welded) 502 Excessive thickness Poor power control (poor U/I match) Welding speed too slow Poor edge preparation on thick work Insufficient starting current 507 Misalignment Work positioned incorrectly Incorrect welding sequence 508 Angle defect Excessive welding power Incorrect welding sequence 509 Collapse Wire speed too fast Torch speed too slow Poor torch guidance 602 Splatter (or beads) Incorrect arc control Problem in electrical contact to ground Defect 300 Defect 402 Defect 402 Defect 502 Defect 507
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ALUMINIUM IN COMMERCIAL VEHICLES
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Aluminium in Commercial Vehicles ha
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VII. FABRICATION . . . . . . . . .
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CHAPTER II ALUMINIUM IN TRANSPORT 1
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EUROPEAN ALUMINIUM ASSOCIATION ALUM
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CHAPTER III WHY USING ALUMINIUM 1.
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CHAPTER IV FREQUENTLY ASKED QUESTIO
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CHAPTER V ALUMINIUM ALLOYS FOR COMM
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CHAPTER VI DESIGN AND CALCULATION 1
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Page 73 and 74: EUROPEAN ALUMINIUM ASSOCIATION ALUM
Page 91 and 92: CHAPTER VII FABRICATION 1. INTRODUC
Page 107 and 108: CHAPTER VIII WELDING 1. FOREWORD .
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Page 129 and 130: CHAPTER IX OTHER JOINING TECHNIQUES
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Page 145 and 146: CHAPTER XI CORROSION RESISTANCE 1.
Page 153 and 154: CHAPTER XII CLEANING OF ALUMINIUM C
Page 157 and 158: CHAPTER XIII REPAIR OF ALUMINIUM CO
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