Hot cracking in welding is a complex phenomenon due to coupling between process, metallurgy and mechanical loading. A methodology based on process simulation, simple microstructural prediction and a pressure model along columnar grains is developed in order to integrate all factors that influence hot cracking. The model is based on some developments of Rappaz, Drezet and Gremaud and takes into account the influences of grain morphology, mechanical and welding thermal loading, on hot cracking. The model based on the microstructure behaviour is able to predict crack onset location in columnar grains on 6061 aluminium alloy.
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