Cryogenics 41 (2001) 475483

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Eect of welding structure on high-cycle and low-cycle fatigue properties for MIG welded A5083 aluminum alloys at cryogenic temperatures
Tetsumi Yuri a,*, Toshio Ogata a, Masahiro Saito b, Yoshiaki Hirayama b
b a National Institute for Materials Science, 1-2-1, Sengen, Tsukuba, Ibaraki 305-0047, Japan Nagasaki R&D Center, Mitsubishi Heavy Industries Ltd, 5-717-1, Hukahori-machi, Nagasaki 851-0301, Japan

Received 18 December 2000; accepted 8 May 2001

Abstract High-cycle and low-cycle fatigue properties of aluminum alloy A5083 base and A5183 weld metals and the eect of welding structure on their fatigue properties have been investigated at cryogenic temperatures in order to evaluate the long-life reliability and safety of the structural materials used in liquid hydrogen supertankers and storage tanks and to develop a welding process for these applications. In the high-cycle fatigue tests, the SN curves of A5083 base and A5183 weld metals shifted to higher stress levels, i.e., the longer life side at lower test temperatures. The ratios of 106 -cycles fatigue strength (FS) to tensile strength (TS) for A5183 weld metals were slightly lower than those of A5083 base metals at each test temperature. Although the ratios of FS to TS for austenitic stainless steels weld metals at 4 K decreased substantially to about 0.4, that of A5183 weld metal was 0.65 even at 4 K and it indicated an excellent high-cycle fatigue property. Fatigue crack initiation sites in A5183 weld metals were occurred from the blowholes if the blowholes were located in the vicinity of the specimen surfaces. However, eects of the blowholes on high-cycle fatigue properties are not clear or signicant. In the low-cycle fatigue tests, the fatigue lives of A5183 weld metals were slightly shorter than those of A5083 base metals at cryogenic temperatures. However, the fatigue lives of A5183 weld metals at 4 K were superior to that of conventional A5083 weld metals. The deterioration of low-cycle fatigue properties of A5183 weld metals at cryogenic temperatures were due to the intergranular fracture surface observed in fatigue crack propagation regions. 2001 Published by Elsevier Science Ltd.
Keywords: Aluminum alloy; MIG weld; Cryogenic temperatures; High-cycle fatigue property; Low-cycle fatigue property; Welding structure

1. Introduction There have been growing concerns about the environment in recent years, with increasing importance being placed on global environmental problems such as global warming or the eects of greenhouse gases on humans. Under such circumstances, clean and renewable natural energies are expected to replace current fossil fuels as next-generation energies. The eective use of large-scale structures for hydrogen is currently being studied, such as storage tanks or supertankers for liquid hydrogen [1,2]. However, there are concerns that the structural materials used in such large-scale structures for handling liquid hydrogen may be subjected to highly

Corresponding author. Tel.: +81-298-59-2542; fax: +81-298-592501. E-mail address: yuri.tetumi@nims.go.jp (T. Yuri).

rigorous service conditions that dier from the conventional conditions, such as long-term use in cryogenic temperatures, hydrogen environment, the application of various welding processes, and complicated loading conditions. In order to guarantee the long-life reliability and safety of cryogenic machinery used under harsh operating conditions such as cyclic loading and deformations, the securing of safety evaluations for fatigue is considered to be particularly important. For example, liquid hydrogen storage tanks may be cyclically stressed by temperature variations due to the amount of liquid hydrogen when it is injected or discharged, and liquid hydrogen supertankers may be cyclically stressed by the wave motion in maritime transportation. Therefore, the evaluation of fatigue properties is a critical issue for material selection and container design. Among aluminum alloys, AlMg alloy A5083 has been widely used for liqueed natural gas (LNG) tanks to date because of its excellent strength and weldability.

0011-2275/01/$ - see front matter 2001 Published by Elsevier Science Ltd. PII: S 0 0 1 1 - 2 2 7 5 ( 0 1 ) 0 0 1 0 0 - X

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In addition to austenitic stainless steels, aluminum alloys, which have good resistance to embrittlement by hydrogen, are considered to be potential materials for liquid hydrogen storage tanks and supertankers [1,2]. However, there are few reports on the fatigue properties of A5083 welds at cryogenic temperatures [37]. In particular, few studies have been systematically conducted on the eects of the welding structure, which has a long-life eect on fatigue properties below the temperature of liquid hydrogen. Among the reports on the fatigue properties of A5083 weld metals at cryogenic temperatures, Suzuki et al. [8] have reported on low-cycle fatigue tests. This report focuses on the use of aluminum alloys as a structural material at cryogenic temperatures due to the fact that fatigue properties of A5083 weld metals are signicantly decreased at 4 K, although they are decreased less at room temperature than A5083 base metals. The report by Suzuki et al. does not mention any results for the fractography of the specimens, and the details of the eects of the welding structure on fatigue properties are not clear. However, it is considered that welding defects, such as blowholes, caused the signicant eect on decreasing the fatigue property at 4 K. It is well known that welds in aluminum alloys are more likely to produce blowholes, and this is one of the defects compared with other metals. The eects of blowholes on mechanical properties depend on their size, number, shape, and distribution [9,10]. In particular, the fatigue properties are considered to be more readily aected by the blowholes [10,11]. As previously reported by the authors [12], the decrease in high-cycle fatigue properties of SUS304L weld metals was due to the blowholes, and this was particularly noticeable below 77 K. It is, therefore, concerned that blowholes in weld metals of aluminum alloys may aect fatigue properties at cryogenic temperatures. In this study, the authors have investigated high-cycle and low-cycle fatigue properties of A5083 welds and discussed the eects of welding structure on their fatigue properties at cryogenic temperatures. 2. Experimental procedure 2.1. Materials The material used in this study was A5083, a commercial aluminum alloy. The weld metal was made by
Table 1 Chemical compositions of A5083 base and A5183 weld metals (wt%) Materials A5083 (Base) A5183 (Weld) Si 0.14 0.10 Fe 0.19 0.17 Cu 0.03 0.02 Mn 0.70 0.66

joining plates 40t mm 270w mm 600L mm by means of metalinert-gas (MIG) welding. The welding direction was parallel to the rolling direction of the base material. The conguration of the joint groove was X-shaped and the weld was completed in two passes using A5183WY wires. The welding condition was with a voltage of 33 V, a current of 720 A for the rst pass and was with a voltage of 34 V, a current of 780 A for the second pass, and a welding speed of 32 cm/min, respectively. Quality of the weld metals passed with JIS 1 grade by non-destructive screening tests and X-ray inspections, as according to JIS Z 3105. The chemical compositions of A5083 base and A5183 weld metals are shown in Table 1. The dimensions of the fatigue specimens are shown in Fig. 1. High-cycle fatigue test specimens (Fig. 1(a)) were the hourglass type with a minimum waist diameter of 6 mm. Low-cycle fatigue test specimens (Fig. 1(b)) were 8 mm in reduced section diameter and 12 mm in gauge length. The specimens of base metals were cut in perpendicular to the rolling direction and those of A5183 weld metals were cut in perpendicular to the welding direction from the second pass in the weld. The specimens were ground longitudinally by hand with SiC paper, and then polished successively using 1 and 0:05 lm alumina powder in aqueous suspension. Tensile properties of A5083 base and A5183 weld metals at each test temperature are summarized in Table 2.

Fig. 1. Dimensions of fatigue specimens (mm).

Mg 4.73 4.54

Cr 0.08 0.08

Zn 0.01 0.01

Ti 0.02 0.03

Al Bal. Bal.

T. Yuri et al. / Cryogenics 41 (2001) 475483 Table 2 Tensile properties of A5083 base and A5183 weld metals at 293, 77 and 4 K Materials A5083 (Base) T (K) 293 77 4 293 77 4 YS (MPa) 153 168 192 139 165 187 TS (MPa) 310 433 577 281 396 484 e (%) 18.1 36.3 30.3 22.8 29.6 20.3 / (%) 30.7 32.5 35.4 37.8 26.3 21.3 E (GPa) 72 74 83 67 71 66

477

A5183 (Weld)

T: temperature; YS: yield strength; TS: tensile strength; e: elongation; /: reduction of area; E: Young's modulus. (The number of tested specimens was 2 for each material and temperature.)

2.2. High-cycle fatigue test The testing machine was a servohydraulic model with a dynamic load capacity of 50 kN. A sinusoidal cyclic axial load with a stress ratio of R 0:01 (minimum load/ maximum load) was applied. Fatigue tests were carried out in liquid helium (4 K), in liquid nitrogen (77 K) and at room temperature (293 K). In 4 K tests, a recondensation-type refrigerator [13] was used to keep the liquid helium level constant during the test. To avoid specimen heating as a result of cyclic loading, the tests at 4 K [14] were carried out at a testing frequency of 4 Hz in the range of fewer than 106 cycles and those over 106 cycles at 10 Hz. The frequency in the 77 and 293 K tests was 10 Hz. The maximum measurable fatigue life in the present study at 4 K was restricted to around 106 cycles due to various limitations related to long-term testing. For the fatigue strength mentioned herein, 106 -cycles fatigue strength (FS) is used, which is considered to be sucient for practical use. 2.3. Low-cycle fatigue test Fully reversed axial-strain controlled fatigue tests were carried out with a closed-loop electrohydraulic machine of 100 kN loading capacity at 293, 77 and 4 K. Cyclic straining was continued until mechanical failure or until the given number of cycles was attained.

In this study, the fatigue life Nf is dened as the number of cycles required to reduce maximum stress rmax to a value of 3/4 times the peak value experienced during testing. The axial-strain was measured by an extensometer mounted on the specimen and controlled to generate a triangular waveform of cyclic ramp at the constant strain rate of 0.4%/s, according to JIS Z 2283. The fatigue test began with a compressive half-cycle. 2.4. Observation of microstructure and fracture surface The microstructures of A5083 base and A5183 weld metals were observed by optical microscopy. The fracture surfaces of fatigue specimens were also examined using scanning electron microscopy (SEM). X-ray energy dispersion spectroscopy (EDS) was utilized for chemical analysis of the microstructure. 3. Results and discussion 3.1. Microstructures Fig. 2 shows optical micrographs of A5083 base and A5183 weld metals. In the base metal, grains are elongated in the hot rolling direction, and the crystallized particles of about 10 lm in size are scattered. In A5183 weld metals, dispersed and crystallized particles of

Fig. 2. Optical micrographs of A5083 base and A5183 weld metals.

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several micrometers in size are observed. The composition analysis of the crystallized particles using EDS revealed that those of the base metals were mainly composed of Al, Fe and Mn, whereas those of the A5183 weld metals were mainly Al, Si and Mg, respectively. However, weld defects such as blowholes and deposited metal cracking were not detected by means of screening tests or microscopy in the weld metals. 3.2. High-cycle fatigue tests 3.2.1. High-cycle fatigue properties Fig. 3 shows the SN curves of A5083 base and A5183 weld metals at each test temperature. The SN curves of A5083 base and A5183 weld metals shifted to the higher stress levels, i.e., the longer life side, at lower test temperatures. The fatigue properties of A5083 base metals are higher than those of A5183 weld metals at all test temperatures, and the dierence gradually increases at lower test temperatures. The FS as a function of test temperatures for A5083 base and A5183 weld metals is shown in Fig. 4, indicating the results of this dierence. Fig. 5 shows the ratio of FS to yield strength (YS) and tensile strength (TS) as a function of test temperatures for A5083 base and A5183 weld metals. In general, the FS remains proportional to TS even at cryogenic temperatures. The authors have previously reported [12,15] that the ratios of FS to TS remain almost constant at 0:50:8 and/or slightly increase with decreased test temperature. On the other hand, the ratios of FS to TS for austenitic stainless steels weld metals were 0:350:7, falling below those of A5083 base metal with decreased test temperature [12]. However, the ratios of FS to TS for A5183 weld metal are slightly lower than those of A5083 base metal at all test temperatures, and both are between 0.6 and 0.7, as shown in Fig. 5. In contrast with austenitic stainless steels weld metals, A5183 weld metal

Fig. 4. The FS as a function of test temperatures for A5083 base and A5183 weld metals.

Fig. 5. The ratio of FS to YS and TS as a function of test temperatures for A5083 base and A5183 weld metals.

shows excellent fatigue properties even at cryogenic temperatures. Yield strength is a very important index for the selection of structural materials, and that a comparison with fatigue properties is also important. As shown in Fig. 5, the ratios of FS to YS for A5083 base and A5183 weld metals increase at lower test temperatures. The ratios of FS to YS for A5183 weld metals are lower than those of A5083 base metals at 77 and 4 K, with the values of 1.5 or more. 3.2.2. Fracture surface of high-cycle fatigue specimen and fatigue crack initiation site Fig. 6 shows typical SEM fractographs of the fracture surfaces of the high-cycle fatigue specimens for the A5083 base metals tested at each test temperature. SEM observation revealed all the fatigue crack initiation sites in the A5083 base metals to be initiated at the specimen

Fig. 3. SN cruves of A5083 base and A5183 weld metals at 293, 77 and 4 K.

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Fig. 6. SEM fractographs of the fracture surfaces of the high-cycle fatigue specimens for the A5083 base metals tested at 293, 77 and 4 K.

surfaces at all test temperatures. In the nal fracture region of fracture surface of high-cycle fatigue specimens at 77 and 4 K, laminated fracture surface [1619] similar to that observed on fracture surface of tensile specimen at the same test temperature can be observed. As the laminated fracture surface is reported to occur on fracture surface of impact specimen at low temperature, they appear in parallel to the rolling direction [18]. This laminated fracture surface is mainly due to the brittleness of the interfacial bonding strength between the crystallized particles and the matrix phase [5] and the precipitation of b-phase at grain boundary [18,19]. On the other hand, fatigue crack initiation sites of A5183 weld metals were observed in the internal specimens, and are shown by the H mark in Fig. 3. Fig. 7 shows SEM fractographs of the fracture surfaces of the high-cycle fatigue specimen for the A5183 weld metal tested at 4 K. As claried by the SEM fractograph in Fig. 7(b), in which fatigue crack initiation site is magnied, it is a blowhole that is produced during welding. The surface of the blowhole has a dendrite pattern formed during the solidication. The blowhole is located in the vicinity of the specimen surface, and the diameter is extremely small at about 50 lm. Therefore, the blowholes of this diameter are defective within the permissible range of JIS 1 grade by non-destructive screening tests using X-rays, although they may act as stress concentration sites in high-cycle fatigue tests. Despite the fact that the blowholes are fatigue crack initiation sites, the ratios of FS to TS for A5183 weld metals are excellent even at cryogenic temperatures as

mentioned in Section 3.2.1, and the blowholes do not aect the fatigue properties. The laminated fracture surface was not observed in A5183 weld metals. However, as shown in Fig. 7(c), an intergranular fracture surface was observed in the nal fracture region. It was also observed in A5183 weld metals tested at 77 K. The SEM fractograph in Fig. 7(c) reveals the presence of many crystallized particles and holes with a size of several lm on the fracture surface. These holes are considered to be due to traces of the crystallized particles produced by the failure of the specimen. Figs. 8(a) and (b) show the diameter of the blowhole, (a), and the location of the blowhole, (b), of the internal crack initiation sites for A5183 weld metals, respectively. The blowhole diameter was determined as virtually circular with d as the diameter. In A5183 weld metals, the blowholes with diameters of 4090 lm were one digit smaller than those of SUS304L weld metals reported previously by the authors [12]. Therefore, this is considered that the A5183 weld metal has excellent fatigue properties even at cryogenic temperatures. Moreover, the diameter of the blowholes tends to decrease as the peak cyclic stress (PS) increases, although the number of data is not enough. On the other hand, those of the blowholes in Fig. 8(b) were measured as the shortest distance from the blowhole to the specimen surface. The distance of the blowholes in A5183 weld metals was mostly concentrated between 2 and 20 lm (3000 lm to the center of the specimen), and that they were located in the vicinity of the specimen surface. Therefore, taking the results of the diameter of the blowholes in Fig. 8(a)

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Fig. 7. SEM fractographs of the fracture surfaces of the high-cycle fatigue specimen for the A5183 weld metal tested at 4 K.

Fig. 8. Diameter of the blowhole, (a), and location of the blowhole, (b), of the internal crack initiation sites for A5183 weld metal.

into consideration, no correlation between the size and the location of the blowholes was found. Moreover, although the blowholes were observed on the fatigue fracture surface in the case of PS 317 MPa at 77 K, this did not occur at a fatigue crack initiation site. The blowhole with a diameter of 75 lm was the same as those of the fatigue crack initiation sites, but the distance of the blowhole from the specimen surface was about 500 lm. Therefore, this blowhole may not act as a stress concentration site, and the fatigue crack occurred from the specimen surface. In general, fatigue cracks in metal are understood to occur on the specimen surface due to the irreversible process of extrusion and intrusion through slip deformation. However, internal fatigue crack initiation is usually associated with the presence of inclusions and pores. Murakami [20] has reported that the maximum stress intensity range, DKImax , at the crack tip of the surface defect is greater than that of the internal defect. On the other hand, when the pre-existing defect is very small, the fatigue strength is hardly aected and if the size of this pre-existing defect is the same, the fatigue strength of the pre-existing defect of the near specimen surface is lower than that of the internal pre-existing defect [21]. Although the blowholes in A5183 weld metals may act as stress concentration sites, resulting in the fatigue crack initiation site, no signicant eect of the blowholes is recognized on the high-cycle fatigue properties. This is attributed to the fact that the TS of A5183 weld metals is low and the size of the blowholes is small. According to the equations by Murakami [20], the

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values of DKImax for A5183 weld metals p are estimated in a range between 1.5 and 2:1 MPa m. These values almost agree with the data in Murakami's report [20], but since there are few data on this issue, it is necessary to conduct a detailed review of the fatigue crack initiation in the existence of the blowhole by additional experiments. 3.3. Low-cycle fatigue tests 3.3.1. Low-cycle fatigue properties Fig. 9 shows the change of maximum stress with an increased number of cycles for A5083 base and A5183 weld metals at each test temperature. The total strain range Det of each curve is indicated in parentheses. Maximum stress of A5083 base and A5183 weld metals at all test temperatures increased more gradually as the number of cycles increases. The hardening of both increases at lower test temperatures, with this eect being more conspicuous in A5083 base metals than in A5183 weld metals. Fig. 10 illustrates the total strain range vs. the number of cycles to failure of A5083 base and A5183 weld metals at each test temperature. The fatigue lives of A5083 base and A5183 weld metals increased at lower test temperatures except for an A5183 weld metal at 4 K and Det of 1.4%. The increase of the fatigue life at lower temperatures is considered to be due to a decrease in the plastic strain range Dep resulting from increase of YS. The fatigue lives of A5083 base and A5183 weld metals at 293 K appeared nearly equal. However, the fatigue lives of A5183 weld metals are shorter than those of A5083 base metals at 77 and 4 K, particularly decreases by 20%

Fig. 10. Total strain range vs. the number of cycles to failure of A5083 base and A5183 weld metals at 293, 77 and 4 K.

in the strain range at 4 K. This decrease is discussed in Section 3.3.2. We compared with our data of low-cycle fatigue tests on A5356 weld metals reported to date by Suzuki et al. [8]. The chemical compositions of the each weld are slightly dierent since the wires are not the same. Tensile properties, such as YS, TS and elongation, are not signicantly dierent for each base and weld metals even at 4 K. Although the fatigue property of A5356 weld metals at 293 K was slightly shorter, there were no signicant dierences between them. However, the fatigue lives at 4 K of A5356 weld metals were substantially shortened by about 30% in the strain range compared with that of A5183 weld metal. Suzuki et al. [8] con-

Fig. 9. Change of maximum stress with an increased number of cycles for A5083 base and A5183 weld metals at 293, 77 and 4 K.

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sidered the deterioration of the fatigue property for the A5356 weld metal at 4 K to be attributable to decrease of ductility. 3.3.2. Fracture surface of low-cycle fatigue specimen and fatigue crack initiation site All of the fatigue crack initiation sites of A5083 base metals occurred at the specimen surfaces at each test temperature. The laminated fracture surfaces, which were observed in the nal fracture regions of highcycle fatigue specimens at 77 and 4 K, were also observed on those of low-cycle fatigue specimens in the nal fracture regions which were produced by forcible fracture. On the other hand, the fatigue crack initiation site occurred from the internal specimen when Det 0:6% at 293 K in the case of A5183 weld metals, whereas others occurred from the specimen surfaces. Fig. 11 shows SEM fractographs of fracture surfaces of low-cycle fatigue specimens tested by Det 0:6% at 293 K for A5183 weld metals. Fig. 11(b) shows an SEM fractograph in which the fatigue crack initiation site is

magnied; this is the same blowhole, the surface of the blowhole has a dendrite pattern formed during the solidication, as observed on fracture surfaces of highcycle fatigue specimens. The diameter is 110 lm and the distance from the specimen surface is at 15 lm, which is very close to the specimen surface. Although blowholes were observed on fracture surfaces of three other specimens, they did not become fatigue crack initiation sites. The diameter was 100 lm, which was almost the same as that of the fatigue crack initiation site for Det 0:6% at 293 K. However, the distance from the specimen surface was longer: 4502250 lm (4000 lm to the center of the specimen). Therefore, it is considered that the blowhole of the specimen for Det 0:6% at 293 K, became a stress concentration site since the distance from the specimen surface of the blowhole was shorter than the other three cases. In the case of low-cycle fatigue tests, fatigue crack initiation almost occurred in the vicinity of the specimen surface. This is considered to be mainly caused by the amount of strain in the lowcycle fatigue tests being greater than that in the highcycle fatigue tests.

Fig. 11. SEM fractographs of fracture surfaces of low-cycle fatigue specimens for A5183 weld metals tested at 293 K: (a) fatigue crack intitiation site; (b) magnied image as shown by arrow in (a).

Fig. 12. Typical SEM fractographs of fracture surfaces of low-cycle fatigue specimens for A5183 weld metals tested at 4 K. Photo (b) is a magnied photo of (a).

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Fig. 12 shows typical SEM fractographs of fracture surfaces of low-cycle fatigue specimens for A5183 weld metals tested at 4 K. Fig. 12(b) shows an SEM fractograph in which the fatigue crack propagation region is magnied and this represents an aspect of the intergranular fracture surface. Such intergranular fracture surfaces were also observed at 77 K. The fatigue lives of A5183 weld metals were shorter than those of A5083 base metals at 77 and 4 K. This is considered to be chiey caused by intergranular fracture surfaces. The intergranular fracture surfaces were not found in the fatigue crack propagation region of fracture surfaces of highcycle fatigue specimens. As shown in Fig. 7(c), however, the intergranular fracture surfaces were observed in the nal fracture region of the high-cycle fatigue specimens and were also observed on fracture surfaces of tensile specimens at cryogenic temperatures. That is, the appearance of intergranular fracture surface in each case could be attributed to the dierence of the fracture mode according to the amount of deformation at the failure. We expected that low-cycle fatigue properties of A5183 weld metals at cryogenic temperatures would be more improved in the case of crystallized particles minimized by an improvement of the welding process. 4. Conclusions High-cycle and low-cycle fatigue properties of aluminum alloy A5083 base and A5183 weld metals and the eect of welding structure on their fatigue properties were investigated at cryogenic temperatures. The main results obtained are as follows: (1) In the high-cycle fatigue tests, the SN curves of A5083 base and A5183 weld metals shifted to higher stress levels, i.e., the longer life side, at lower test temperatures. The SN curves of A5083 base metals are higher than those of A5183 weld metals at all test temperatures. (2) The ratios of FS to TS for A5183 weld metals were slightly lower than those of A5083 base metals at all test temperatures. Although those of austenitic stainless steels weld metals at 4 K were substantially decreased to about 0.4 [12], that of A5183 weld metals was 0.65 even at 4 K, and it indicated an excellent high-cycle fatigue property. (3) Fatigue crack initiation sites in A5183 weld metals occurred from the blowholes if the blowholes were lo-

cated in the vicinity of the specimen surface. However, eects of the blowholes on high-cycle fatigue properties are not clear or signicant. (4) In the low-cycle fatigue tests, the fatigue lives of A5183 weld metals were slightly shorter than those of A5083 base metals at cryogenic temperatures. However, the fatigue lives of A5183 weld metals at 4 K were superior to those of conventional A5083 weld metals [8]. (5) The deterioration of low-cycle fatigue properties of A5183 weld metals at cryogenic temperatures was due to intergranular fracture surfaces observed in the fatigue crack propagation regions.

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