Experimental Analysis of Toughness in 6156 Al-Alloy Sheet for Aerospace Applications

Analysis of toughness in 6156 Al-Mg-Si-Cu sheet has been performed using enhanced Kahn tear tests on samples quenched at different rates, whilst microstructures of the samples have been assessed using differential scanning calorimetry, scanning electron microscopy and transmission electron microscopy. Crack initiation energies were unaffected by changing water quench temperature from 20°C to 60°C, however a significant reduction was evident on air cooling. Crack propagation resistance was reduced for both 60°C water quenched and air cooled materials. The failure morphology of the air cooled material appears consistent with classical intergranular ductile failure. Coarse voiding and shear decohesion was prevalent in the 20°C water quenched material, whilst the 60°C water quenched material showed a mixture of transgranular and intergranular fracture modes. Changes in microstructure and precipitation behaviour resulting from reduced quenching rate were identified and related to the observed fracture behaviour, particularly in terms of precipitate free zone formation and the simultaneous presence of coarse particles at grain boundaries.