研究目的
To investigate the weld pool dynamic behavior and the formation mechanism of keyhole-induced porosity in laser + metal inert gas (MIG) hybrid fillet welding of aluminum alloy in the horizontal position.
研究成果
The developed three-dimensional transient model accurately simulates the temperature field, fluid flow, and formation process of porosity in hybrid horizontal fillet welding. Keyhole-induced porosity is mainly formed near the keyhole bottom and the upper fusion line of the weld bead. The larger hybrid weld pool reduces porosity, but the capture of bubbles by the upper molten pool edge increases the possibility of porosity formation.
研究不足
The model's accuracy is limited by the insufficient accuracy of the thermal–physical properties of the aluminum alloy at high temperature and the simplification of parts of the submodels.
1：Experimental Design and Method Selection:
A three-dimensional transient model was developed to simulate the weld pool dynamic behavior, including the coupling of the keyhole, droplet, and weld pool, as well as the heat and mass exchange between gas and liquid phases.
2：Sample Selection and Data Sources:
The base metal was 6061 aluminum alloy, and the filler metal was 5356 aluminum alloy wire. X-ray nondestructive testing technology was used to measure the pore distribution and size inside the weld metal.
3：List of Experimental Equipment and Materials:
A fiber laser with a maximum power of 6 kW, welding current and arc voltage of 200 A and 18 V, respectively, and a welding speed of
4：8 m/min were used. Experimental Procedures and Operational Workflow:
The model was solved using ANSYS Fluent software, employing the finite volume method (FVM) for the governing equations.
5：Data Analysis Methods:
The temperature field, fluid flow, and formation process of porosity were analyzed based on the calculated and experimental results.
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