The susceptibility to solidification cracking was predicted for aluminium welds of 2024 Al made with filler metals 2319, 4043 and 4145 Al and of 6061 Al made with filler metals 4043 (traditional) and 4943 Al (new, higher strength). The maximum |dT/d(fS)1/2| (T: temperature; fS: fraction of solid) was used as the crack susceptibility index. In each case, the index was calculated using the weld metal composition based on the measured dilution level. The predicted crack susceptibility decreased in the order of 2319 Al, 4043 Al and 4145 Al for 2024 Al, and was similar between 4043 Al and 4943 Al for 6061 Al. These predictions agreed well with the experimental results of recent crack susceptibility tests of these welds.
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