Inherent Difficulty in Manufacturing Small Fillet Welds in 6000 Series Aluminum

The lesson learned is that when producing small size fillet welds in 6000 series aluminum there is an inherent risk that the welded part can be produced in accordance with approved manufacturing standards and inspection techniques, and yet result in a weld that has subsurface cracks. These cracks can result in a part with less than the required design strength and fail under load. The recommendation is that designers should be trained to understand the risk inherent in designing load carrying parts that incorporate critical welds in 6000 series aluminum.

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