Unveiling Liquation and Segregation Induced Failure Mechanism in Thick Dissimilar Aluminum Alloy Electron-Beam Welds

This study presents new findings on the underlying failure mechanism of thick dissimilar electron-beam (EB) welds through a AA 2219-AA 5083 pair. Contrary to prior studies EB welding thin Al alloys, where liquation in grain boundaries (GBs) partially melted zone (PMZ) was not observed, present investigation for reports both and increased segregation Cu PMZ. The work is thus directed towards understanding unusual observation PMZ weld microstructural variation across various regions produced weld. results are correlated with mechanical properties weld, i.e., hardness tensile response. Results this suggest that unlike convention produces sound welds, performance affected by heat input, associated cooling rates, most importantly base material thickness. Extensive induced 2219 side explained heat-transfer analysis. Beyond certain plate thickness, transfer changes from two three-dimensional. As result, retarded promotes welds.