A solidification and microstructure modelling approach has been developed to predict weld metal and heat affected zone (HAZ) characteristics. The freezing range and phase evolution in the weld metal region were predicted using thermodynamic and diffusion controlled growth calculations. The calculated freezing range was correlated with the weld solidification cracking tendency. A simplified analytical model was suggested to describe thermal cycles that are experienced by the HAZ. This analytical model was coupled with a published microstructure model for age hardenable alloys to predict the hardness variations across the HAZ. The above integrated approach was evaluated using experimental welds made on nonage hardenable 5754 (Al–Mg) and age hardenable 6111 (Al–Mg–Si) alloys using gas tungsten arc, electron beam, and gas metal arc welding processes.
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