WELD 1410 – Metallurgy and Material Testing

 Average 5 out of 5

For students with experience in welding but not in metallurgy. Atomic bonding, defects in metal crystals, and weld microstructure in aluminum alloys.



The microstructure of aluminum welds will be revealed in the laboratory using standard metallographic techniques. Defects such as extraneous particles, porosity, and flaws (such as cracking) will be noted and recorded digitally in micrographs (pictures). Digital recording and analysis of the weld microstructures will be accomplished with an upright metallurgical microscope. Microhardness measurements will be made across each weld zone using a microhardness tester. The microstructure of the aluminum alloy welds will finally be related to welding parameters and weld integrity.


The course learning outcomes are to have students:

  1. Describe basic physical metallurgy starting at the atomic level, with bonding, defect structure, phase diagrams and diffusion and moves towards the development of metal microstructure.
  2. Describe how metals solidify, how phases nucleate and grow, and the mechanisms by which metal alloys are strengthened. Describe the development of the fusion and heat-affected zones during the welding of aluminum.
  3. Describe how weld variables such as pool shape, travel speed, cooling rate and other variables affect the subsequent weld microstructure.
  4. Determine how the weld variables and weld microstructure affect the mechanical properties of the weld will be able to identify the microstructure of acceptable welds.
  5. Prepare metallographic samples of aluminum alloy welds in the laboratory to reveal their microstructure. Measure and interpret the microhardness across a weld.

This material is based upon work supported by the National Science Foundation under Grant No. 1400593. Any opinions, findings, and conclusions or recommendations expressed in this material are those of the author(s) and do not necessarily reflect the views of the National Science Foundation.

Materials Lightweighting
Product Lifecycle:
Pre-production: Research, Design, Development, Testing, and Tooling
Production: Manufacturing, Assembly, and Operations
Resource Type:
Classroom Activity
Lab Activity
Lesson Plan
Roane State Community College
Author & Title:
Dave Braski
Date Developed:
Monday, May 01, 2017
Welding,metallurgy,bonding,aluminum alloys
Education Level:
Undergrad Students (13-14)