ESAB offers a complete line of welding and cutting products and solutions. Explore our equipment offering with ease based on product line and industry.
ESAB is a world leader in welding and cutting equipment and consumables. Explore our complete line of welding & cutting products for virtually every application.
ESAB University Courses are incremental, structured learning modules designed to help you take your skills to the next level. New courses are being added regularly, so please check back often. Click the link to see current courses offered.
Articles cover industry topics more in-depth and are created in partnership with ESAB engineers and master welders. Click the links to see the latest.
Tips from ESAB Experts to help take your welding, cutting and fabrication skills to the next level.
ESAB Courses are structured learning designed to help welders achieve certain learning milestones and explore topics more in-depth. Check back often for updated resources.
ESAB University videos are curated with tips and best practices from top fabricators around the world. Learn new techniques or improve your current skills with ESAB University videos.
Enhance your knowledge of welding, cutting, and fabrication with free and accessible webinars on a variety of topics, including welding best practices, tips for using ESAB products, new product launches, and more, presented by trusted ESAB experts.
ESAB is a world leader in welding and cutting equipment and consumables. We offer a complete line of fabrication solutions for virtually every application.
ESAB Newsroom - Stay up to date with the latest news from ESAB. View press releases, product announcements, corporate news, and more here.
ESAB EHS (Environment, Health & Safety) initiatives are monitored with the highest degree of importance and commitment to safety is ingrained in our culture.
The history of ESAB is the History of Welding. Go here to view an interactive look at ESAB's history in shaping the future of innovation in welding, cutting, and fabrication.
View available job openings and more on the ESAB Careers page.
ESAB is recognised for its adherence to the best industry practices and commitment to its employees and customers. Explore our list of prestigious awards that we have been honoured with!
Purchasing from an ESAB Authorised Distributor guarantees you first-class customer service and support for all ESAB products.
ESAB offers a wealth of product support resources, including a range of technical and service publications, from Safety Data Sheets and downloadable product manuals to product certifications.
Visit ESAB's global manual search engine to access the items below and more.
Global User Manuals
Instruction Manuals
Spare Parts List
Product Storage Instructions
View Main Contact Page
View ESAB Location Information
+91 44 4228 1100
No playlist found! Your playlist can be created here.
Filler Metals
Most welders face problems passing a GMAW (Gas Metal Arc Welding) procedure qualification test for a groove weld with 6061-T6 base material. In this case, welders find it difficult to obtain the minimum tensile strength as required by the welding code. There does not appear to be any significant weld discontinuities within the sample, and it passes guided bend tests. The transverse tension test specimens fail in the heat-affected zone and not the weld. However, the calculated tensile strength is lower than that of those shown in table 4.2 of AWS (American Welding Society) D1.2-97 Structural Welding Code - Aluminum.
The most common reason for a weld made in this base material, which is free from major discontinuities, not to meet the minimum tensile requirement, is overheating of the base material during the welding process.
To understand why this problem can occur, we must first understand the characteristics of the 6xxx series base materials. This series of aluminum alloys is one of the heat treatable series, which acquire their strength through a process of thermal treatments. They are often used in the -T6 condition, which indicates that they have been solution heat-treated and artificially aged.
Heating base material -The -T6 condition is achieved by heating the base material to a temperature of around 990 °F. This step in the operation is necessary in order to dissolve the major alloying elements into solution. The heating process is then followed by quenching, usually in water, in order to trap the alloying elements and produce a supersaturated solution. In the case of the 6xxx series alloys, the major alloying elements are magnesium and silicon, which combine during the thermal treatment to form magnesium silicide.
Artificial aging -After solution heat treatment, the material is reheated to a lower temperature (around 320 °F) and held at a temperature for a predetermined time. This second thermal treatment is termed artificial aging and is conducted to precipitate a portion of the elements or compounds back out of the supersaturated solution to enhance the mechanical properties of the material.
When we consider the controlled heat treatment that has been conducted on these materials prior to welding, to obtain the -T6 condition, we can appreciate their response to the arc welding process, which heats the material to the same temperatures in an uncontrolled manner. The 6061-T6 base materials, as purchased, have a typical tensile strength of 45 ksi before welding.
The AWS D1.2 Structural Code has recognized the metallurgical changes that occur to this base material from the exposure to heat during arc welding, and consequently, requires a minimum tensile strength of 24 ksi. The minimum tensile strength specified by the code is based on historical testing using a variety of welding procedures.
If we consider the fully annealed typical tensile strength of 6061 as being 18 ksi, we can appreciate the importance of controlling the overall heat input during the arc welding process. There is a direct association between the total welding heat input and mechanical properties of the base material adjacent to the weld (the heat affected zone) after welding. The higher the total heat input, the lower the tensile strength can be expected to fall.
In order to meet the minimum tensile strength requirements of the code, we need to closely control our welding procedure to prevent overheating of the base material. It is important to consider the below techniques:
Size of test sample - First, we must consider the size of the test samples being welded. The code provides minimum dimensions for groove weld test plate size. You must comply with this requirement, if practical, use a larger test sample than specified. This will provide for a superior heat sink and lower the possibility of excessive overheating and prolonged time at a temperature within the heat-affected zone.
Preheating and interpass temperature -Secondly, comply with the preheating and interpass temperature requirements of the code, which for this type of material specifies 250 °F as the maximum preheat and interpass temperature. Also observe the holding time at temperature requirement, which is not to exceed 15 minutes. If possible, conduct the certification testing without preheating, or at lower preheating temperatures, and allow the base material to cool too well below the maximum interpass temperature before welding is resumed.
Welding speed -A major contributor to the overall heat input of a weld is the travel speed during the welding process. For this reason, it is preferable to select a welding sequence and technique which makes use of faster stringer type weld beads as opposed to slower weaving techniques.
The above recommendations apply to welding the 6061-T6 base materials with either a 4xxx series or a 5xxx series filler alloy, and regardless of shielding gas type or mixture used.