1. Graduate Research Assistant: Meaghan Ormrod
Supervisors: Dr. Andre Phillion, Dr. Spiro Yannacopoulos
May 14, 2015
RESEARCH OVERVIEW

2. PROJECT OBJECTIVES
• To characterize the fatigue behaviour of AA 5052 through coupon testing to measure:
• Tensile strength/yield strength
• Vickers/Rockwell hardness
• Component level tests performed in conjunction with Northside Industries
• A literature review on fatigue
• To investigate the microstructure relationship to welding through:
• Hardness
• Tensile strength
• Characterization of grain size and precipitation (if present)

3. AA5052 MATERIAL CHARACTERIZATION
COUPON TESTS
• All tests are to be performed on AA5052 coupons.
• Fatigue Tests
• Dimensions to be determined
• As per Dr. Phillion, tests will be performed using the fatigue machine at UBC
Vancouver – compression/tension fatigue
• Tensile Tests
• 24x80mm with an 8x16mm gauge length
• To be performed at UBC Okanagan?
• Hardness Tests
• Dimensions to be determined
• To be performed using the Vickers Hardness Tester at UBC Okanagan

4. AA5052 MATERIAL CHARACTERIZATION
NORTHSIDE INDUSTRIES COLLABORATION
• An automated test apparatus has been designed to perform component-level fatigue
pressurization experiments on 78gal fuel tanks.
• Pressures between 4-20psi will be covered over up to 10,000 cycles – 20 tanks are to be
tested. Testing schedule to be determined.
• The tanks will be equipped with pressure sensors and strain gauges to measure the
material response to the pressurization.
• Once the testing is complete, tensile test specimens will be extracted from the body and
the end caps to determine how the pressurization affects the tensile strength of the
material.
• Hardness profiles will be generated across the weld, and the yield strength will be
measured across the weld.
• The pressurization tests will be performed at Northside Industries in West Kelowna.

5. WELDING EXPERIMENTS
Material
Thickness
Pass No. Filler Metal
Size
Current
Polarity
Welding
Current (A)
Wire Feed
Speed (IPM)
Volts (V) Arc Travel
Speed (IPM)
0.102” 1 0.047” DCRP 155 190 23-24 42
0.102” 1 0.047” DCRP 160 200 23-25 44
0.102” 1 0.047” DCRP 150 180 21-23 40
0.102” 1 0.047” DCRP 165 210 24-26 46
0.102” 1 0.047” DCRP 145 170 20-22 38
0.102” 1 0.047” DCRP 170 220 25-27 48
0.102” 1 0.047” DCRP 140 160 19-21 36
• Test Parameters provided by Mr. Hamid Zareie

6. WELDING EXPERIMENTS - NOTES
• Trim: 50
• Filler Metal: ER 5356
• Shielding Gas: Argon
• Shielding Gas Flow Rate: 60 cu ft/hr
• Use the same joint design: Square groove with backing
• In case of stubbing, increase voltage and trim to create a stable arc
• In case of burning back, lower voltage and trim to create a stable arc

7. ESTIMATED TIMELINE
• AA 5052 Fatigue Characterization
• Coupon Tests and Analysis – Complete by September 2015
• Component Tests – Complete by September 2015
• Component Test Analysis – Complete by November 2015
• Literature Review of Fatigue – Complete by November 2015
• Characterization of Weld Procedure Effect on Weld Quality
• Welding Experiments – Complete by September 2015