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Heat-treatable aluminum alloysAluminum alloys, commonlyHybrid repair techniques used in aerospace and shipbuilding, are susceptible to weld zone failures and the formation of cracks in critical structural locations. Replacing large and expensive components can be time-consuming and costly. In-situ repair methods offer a promising alternative. Fusion-based welding and friction stir processingFriction stir processing (FSP) have emerged as suitable techniques for repairing structures. This study investigates the feasibility of repairing cracks in a plate made of heat-treatable aluminum alloyAluminum alloys 6061-T6 using a hybrid method combining conventional millingMilling, metal inert gas weldingMetal inert gas welding (MIG), and FSP. An optimized heat treatmentHeat treatment method was applied to enhance the properties of the repaired zone to match the base aluminum alloyAluminum alloys. The influence of FSP and heat treatmentHeat treatment was analyzed in detail, with insights into the mechanisms driving microstructure evolutionMicrostructure evolution and mechanical propertyMechanical properties enhancement. This hybrid repair method shows potential as a faster, more efficient alternative to component replacement in real-world applications.

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Hybrid Repair Techniques for Heat-treatable Aluminum Alloys

  • 会议论文

  • 发表日期：

    2025年

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  • Amlan Kar,
  • Landon Zentz,
  • Todd Curtis,
  • Grant Crawford

摘要

Heat-treatable aluminum alloysAluminum alloys, commonlyHybrid repair techniques used in aerospace and shipbuilding, are susceptible to weld zone failures and the formation of cracks in critical structural locations. Replacing large and expensive components can be time-consuming and costly. In-situ repair methods offer a promising alternative. Fusion-based welding and friction stir processingFriction stir processing (FSP) have emerged as suitable techniques for repairing structures. This study investigates the feasibility of repairing cracks in a plate made of heat-treatable aluminum alloyAluminum alloys 6061-T6 using a hybrid method combining conventional millingMilling, metal inert gas weldingMetal inert gas welding (MIG), and FSP. An optimized heat treatmentHeat treatment method was applied to enhance the properties of the repaired zone to match the base aluminum alloyAluminum alloys. The influence of FSP and heat treatmentHeat treatment was analyzed in detail, with insights into the mechanisms driving microstructure evolutionMicrostructure evolution and mechanical propertyMechanical properties enhancement. This hybrid repair method shows potential as a faster, more efficient alternative to component replacement in real-world applications.