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Butt welding-brazing of steel to aluminum by hybrid laser-CMT
摘要： A laser penetration welding-brazing combined with Cold Metal Transfer (CMT) arc, was proposed to improve weld shape and interfacial reaction inhomogeneity of 5052 aluminum alloy and Q235 low carbon steel with ER5356 welding wire in butt joint. The effects of wire feed speed, beam offset and welding speed on weld shape, interfacial microstructures and tensile strength of joints was studied. This method improved the undercut defect existed in butt laser welding-brazing, obtained well-formed joints and promoted the uniform distribution of the interface reaction. The interfacial intermetallic compounds (IMCs) layer consisted of Fe2Al5 and Fe4Al13 and the thicknesses were controlled to 3-5 μm. Microstructures of weld seam was composed of α-Al and Al3Mg2. The brittle IMCs layer thickened and then the tensile strength decreased with increasing the wire feed speed. The thickness of the IMCs layer decreased but weld shape became worse when the welding speed or the offset increased. The tensile strength increased first and then decreased. The highest tensile strength reached higher than 80 MPa and the joint fractured in IMCs layer along the interface.
关键词： intermetallic compound,Laser–CMT arc hybrid welding-brazing,dissimilar metals welding,low carbon steel,aluminum alloy
更新于2025-11-28 14:24:20
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Laser Welding of Dissimilar Metal Joint of 6061 Al Alloy and Al Matrix Composite
摘要： In this paper, dissimilar metal joints of 6061 aluminum alloy and aluminum matrix composite material are investigated by laser welding. TiB2 particles were added into the lap joint. The welding process, microstructure, and the corrosion properties of welding joints are examined. The results demonstrate that the selected optimization process parameters are laser power 6 kW, welding speed 0.6 mm/s, pulse width 11.5 ms, and laser frequency 4.5 Hz. There are a few obvious pores in the molten pool. Al2Ti, Fe2Si, and Al0.5Fe3Si0.5 are present in the microstructure. During the welding process, some TiB2 particles are decomposed and reacted with molten Al. Other TiB2 particles are nucleated and solidi?ed, and the excess TiB2 particles are pushed to the grain boundaries by molten Al. TiB2 particles are wetted well by molten matrix metal. The corrosion resistance of alloys in di?erent conditions decreased in the following order: the weld beam >6061 Al > AMC.
关键词： aluminum matrix composite,laser welding,TiB2 particles,microstructure,6061 aluminum alloy,dissimilar metal joints,corrosion properties
更新于2025-11-21 11:18:25
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Microstructure and mechanical properties of Ti/Al dissimilar joints produced by laser-MIG welding–brazing
摘要： We butt-welded AA6061 aluminum alloy to Ti6Al4V titanium alloy, dissimilar light metals, by using laser-MIG hybrid welding–brazing without grooves. The parameters of the laser and arc were optimized to produce sound joints with good formation and mechanical properties. The microstructure of the layer of intermetallic compounds (IMCs) was investigated by scanning electron microscopy and energy dispersive spectroscopy. We also tested the tensile strength of the joints with and without reinforcement. The morphology and thickness of the IMCs varied throughout the joints. A continuous thin layer of TiAl3 appeared on the top surface of the Ti6Al4V, on which some rod-like IMCs grew toward the fusion zone. In the upper region of the butt plane, because more heat accumulated there from the high-power laser coupled with the MIG arc, double-layer IMCs with a thickness of ～ 10.0 μm formed, composed of TiAl (near the Ti alloy) and TiAl3 (near the fusion zone). In the lower region of the butt plane, the double-layer IMCs became continuous and uniform, the serrated morphology disappeared, and the thickness of the IMC layer decreased to 4.0 μm. On the backside of the joint, the thickness of the compound layer (TiAl3) was about 1.0 μm. The average tensile strengths of the reinforced and unreinforced joints were 226 MPa and 210 MPa, respectively, which are up to 88% and 81% of the AA6061 tensile strength, respectively.
关键词： dissimilar joint,titanium alloy,intermetallic compounds.,Laser-MIG hybrid welding–brazing,aluminum alloy
更新于2025-09-23 15:22:29
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Study on the intelligent model database modeling the laser welding for aerospace aluminum alloy
摘要： With the purpose of improving the modeling e?ciency, the model database is established targeting that in-telligent modeling of laser welding for aerospace aluminum alloy. The model database consists of material database, heat source model database and weld joint structure database. The aerospace aluminum alloys are classi?ed reasonably in order to establish the material model database which can manage the thermo-physical properties of aluminum alloys. The heat source models of laser welding are summarized to establish model database on the basis of the di?erent energy distribution characteristics. The joint structure database includes butt joint, T-joint and lap joint. Modeling of arbitrary structures can be implemented quickly and e?ciently when modelers invoke and assemble this model database. The ?nite element model is e?ciently established and accurately solved by taking the 5A90 and 2219 aluminum alloy laser welding as an example. Finally, it is found that the model database established in this paper can greatly improve the modeling e?ciency of laser welding numerical simulation.
关键词： Laser welding,Model database,Aluminum alloy,Structural model,Heat source model,Material model
更新于2025-09-23 15:21:01
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Effect of laser shock peening on mechanical and microstructural aspects of 6061-T6 aluminum alloy
摘要： Laser shock peening (LSP) of 6061-T6 aluminum alloy was performed and parametric effects post LSP on mechanical aspects and microstructural evolution are meticulously studied using various means of characterization techniques such as residual stress analysis, surface roughness, Vickers microhardness, tensile testing, X-ray diffraction (XRD) analysis, transmission electron microscopy (TEM) and electron back scattered diffraction (EBSD). Work hardened layer of ~1500 μm depth is obtained with significant improvement in cross-sectional microhardness up to 33.04%. Beneficial compressive residual stress of maximum magnitude up to -273 MPa was induced in laser peened specimens concentrating its overall effect around the depth of 100 μm along the effective depth region. Second phase Mg5Si6 (β?) precipitates were observed post LSP while analyzing XRD profiles along with the peak broadening and peak shifting towards higher 2θ angle justifying the results obtained in microhardness profile. High angle grain boundaries (HAGBs) fraction was increased in LSPed specimens and its effect is noticed in residual stress profile. Mg5Si6 (β?) precipitates are attributed as contributing precipitates in improving the mechanical properties of LSPed specimens along with the dense dislocation density caused by severe plastic deformation during LSP. The collective contribution of strain hardening, second phase precipitates, peak broadening, dislocation density and increased fraction of HAGBs is observed in mechanical and microstructural aspects of LSPed specimens. The results are discussed in detailed and are strongly correlated with each other.
关键词： EBSD,Aluminum alloy,cosα method,TEM,XRD,Laser shock peening
更新于2025-09-23 15:19:57
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FIB-SEM Investigation of Laser-Induced Periodic Surface Structures and Conical Surface Microstructures on D16T (AA2024-T4) Alloy
摘要： The use of aluminum alloy AA2024-T4 (Russian designation D16T) in applications requiring a high strength-to-weight ratio and fatigue resistance such as aircraft fuselage often demands the control and modification of surface properties. A promising route to surface conditioning of Al alloys is laser treatment. In the present work, the formation of ripples and conical microstructures under scanning with femtosecond (fs) laser pulses was investigated. Laser treatment was performed using 250 fs pulses of a 1033 nm Yb:YAG laser. The fluence of the pulses varied from 5 to 33 J/cm2. The scanning was repeated from 1 to 5 times for different areas of the sample. Treated areas were evaluated using focused ion beam (FIB)- scanning electron microscopy (SEM) imaging and sectioning, energy-dispersive X-ray (EDX) spectroscopy, atomic force microscopy (AFM), and confocal laser profilometry. The period of laser-induced periodic surface structures (LIPSS) and the average spacing of conical microstructures were deduced from SEM images by FFT. Unevenness of the treated areas was observed that is likely to have been caused by ablation debris. The structural and elemental changes of the material inside the conical microstructures was revealed by FIB-SEM and EDX. The underlying formation mechanisms of observed structures are discussed in this paper.
关键词： femtosecond laser,LIPSS,conical microstructures,aluminum alloy 2024
更新于2025-09-23 15:19:57
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Hot cracking in autogenous welding of 6061-T6 aluminum alloy by rectangular pulsed Nd:YAG laser beam
摘要： Due to high hot crack susceptibility of Al-Mg-Si alloys, autogenous welding by rectangular pulsed laser beam has not been generally successful in the removal of cracks. In this research, the effect of pulsed Nd:YAG laser parameters and preheating on the creation of hot cracks in the 6061-T6 aluminum alloy was investigated. The sample that was fabricated by the laser parameters including 1 Hz, 0.12 mm/s, 10 ms, and without preheating exhibited the highest cooling rate and the smallest dendrite arm spacing but no hot crack was observed. The tensile test specimens of this sample fractured at a point far from the weld metal and a decrease in the precipitation of silicon and magnesium in the inter-dendritic space and the reduction of thermal stresses resulted in the elimination of hot cracks. However, according to macro-scale models for the creation of hot cracks, preheating decreased the tensile stresses in the BTR (brittle temperature range), but increasing the preheating temperature led to increasing rather than decreasing the hot crack length. In this case, the formation of hydrogen porosity, the segregation of silicon and magnesium, and the creation of low melting point compounds were the important parameters affecting the hot crack initiation and growth.
关键词： Laser welding,6061 aluminum alloy,Stress simulation,Solidification microstructure,Hot crack modeling,Rectangular pulse
更新于2025-09-23 15:19:57
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Light incoupling and SPR tailoring of graphene coated silver-aluminum alloys’ dimer in mimicked humid ambient
摘要： This work demonstrates the optical responses of the graphene coated silver-aluminum (Ag-Al) alloys' dimer in the presence of humid ambient using Discrete Dipole Approximation (DDA) as a numerical technique. The non-equivalent spherical shape of graphene coated Ag-Al alloy dimer has been considered for this study, where the plasmonic coupling supports both the bonding and anti-bonding modes which lies in higher and lower wavelength region, respectively. The combined effect of these modes provides a broad resonant spectrum, which is mainly influenced by the inter-particle separation between graphene coated alloy dimer. As the interparticle separation decreases, the resonance wavelength shows a red spectral shift with increase in the magnitude of local electric field. The results of proposed geometry provide a good support for the various applications in photovoltaics and photonics.
关键词： surface plasmon,humidity,graphene,dimer,Silver-aluminum alloy
更新于2025-09-19 17:15:36
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Influence of Magnesium on Spatter Behavior in Laser Deep Penetration Welding of Aluminum Alloys
摘要： The quality of welds, as well as the necessity of post-processing, is challenged by spatter generation during the laser keyhole welding process. In this study, the influence of the magnesium content on spatter behavior is studied for three aluminum alloys (Al99.5, AlMg3, and AlMg5). A synchronized dual high-speed camera system is used to observe the spatter behavior and to reconstruct 3D spatter trajectories as well as determine the characteristics of spatter velocity, flight path angle, and approximate spatter size. The mean spatter velocities and flight path angles of the welding experiments with the three alloys were in welding direction between 4.1 m/s and 4.6 m/s and 44.8°, respectively. Furthermore, the AlMg alloys show excessive spatter behavior with spray events of more than 50 spatters at a time, and less frequently spatter explosions. Spatter spray events show a character similar to spatter explosions. Volumetric evaporation is proposed as effecting these events. In contrast, and resulting from a different mechanism, pure aluminum (Al99.5) shows group ejection events with at least 10 spatters at a time. In this study, there are no correlations between spatter velocities and flight path angles, nor between velocities and approximate spatter sizes.
关键词： high-speed imaging,keyhole welding,aluminum alloy,welding,laser welding,spatter
更新于2025-09-19 17:13:59
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[Laser Institute of America ICALEO? 2016: 35th International Congress on Applications of Lasers & Electro-Optics - San Diego, California, USA (October 16–20, 2016)] International Congress on Applications of Lasers & Electro-Optics - Observation of keyhole and melt pool dynamics in laser welding of Al alloy by x-ray phase-contrast method
摘要： Aluminum alloy is a lightweight material frequently used for automotives parts, batteries, airplanes, etc. to reduce greenhouse gas emissions. A highly efficient and stable laser welding method has long been sought for Al alloy because of its poor weldability due to its high heat conductivity and high reflectivity of 1 μm wavelength laser light. Because welding phenomena and defect formation mechanism are still not properly understood due to their complexity, this research aims to investigate the laser welding phenomena of Al alloy. To understand the weld pool and keyhole dynamics during welding, the weld pool was observed with a high-speed camera and X-ray phase-contrast method. The keyhole behavior and solid-liquid interface during laser welding for A1050 can be observed more clearly than in X-ray absorption-contrast method. At a lower welding speed (0.5 m/min), frequent intensive keyhole expansion and high porosity could be observed. Although high porosity could be observed at a higher welding speed (1 m/min), keyhole expansion was barely observed. It is thought that at a low welding speed, intensive evaporation at keyhole bottom leads to unstable keyhole behavior due to high heat input, and as a result, high porosity is formed due to be intake of air into the keyhole. The effect of fan usage was evaluated. In the case without a fan, intensive keyhole expansion was observed frequently. It is supposed that the laser partly interacted with plume, which led to a sudden evaporation due to laser scattering. It was observed that a bubble from the keyhole bottom moved around the keyhole at a high speed, and the bubble was trapped at a solid-liquid interface. Then the bubble grew by absorbing other small bubbles in a melt pool. In all welding conditions, frequent small expansion at the keyhole bottom was observed. Therefore, the porosity formation mechanism is assumed to have a strong relationship with expansion of keyhole bottom, where major porosity was formed.
关键词： X-ray phase-contrast method,porosity formation,Aluminum alloy,laser welding,weld pool dynamics,keyhole dynamics
更新于2025-09-19 17:13:59