A review: Suppression of the solidification cracks in the laser welding process by controlling the grain structure and chemical compositions

Norouzian, Mohammadhossein; Elahi, Mahdi Amne; Plapper, Peter

doi:10.1016/j.jajp.2023.100139

Cited by 18 publications

(7 citation statements)

References 76 publications

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“…At this zone defined as 'mushy', the solid grains grow and begin to interact with each other at the coherency point and behave like a solid forming skeleton. Therefore, it is possible to say that coherency temperature is the temperature that separates the slurry and mushy zones [31]. After this point, the flow of remaining fluid becomes interdendritic, and with a further increase in f s , the permeability of the mushy zone decreases, leading to pockets of isolated liquid.…”

Section: Solidification Behavior and Crack Sensitivity Of Weld Metalmentioning

confidence: 99%

How to avoid solidification cracking in arc welding of aluminum alloys: a review on weld metal grain refinement approaches

Yolcu,

Kahraman

2023

Mater. Res. Express

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Joining aluminum alloys with arc welding methods is frequently subject to literature and industrial applications. Although aluminum alloys have different difficulties in the arc welded process, the formation and elimination of solidification cracking defects is a more complex phenomenon. Since avoidance of this defect requires specific approaches and methods, special attempts and improvements have been studied frequently on this subject in recent years. Studies in the literature have clearly shown that this defect, which is often encountered in aluminum alloys, takes place along the grain boundaries. Therefore, the major approach to eliminate this defect is activating nucleation and decreasing the grain size. In this context, modification approaches in the literature, which are frequently used for arc welding of aluminum alloys, have been developed to use three different mechanisms including heterogeneous nucleation, dendrite fragmentation, and grain detachment. While it is aimed to increase heterogeneous nucleation by reinforcing filler metals with compounds in the inoculation approach; dendrite fragmentation and grain detachment are also aimed in the approaches where external effects and forces are used. Within the frame of references, it is also possible to review the external factors aiming to improve weld pool convection and thermal conditions under two headings, which are weld pool stirring and pulsed arc current approaches. The weld pool stirring approach also includes ultrasonic treatment and magnetic arc oscillation methods. In this study, solidification cracking defect that frequently occurs in the arc welding of aluminum alloys is explained fundamentally and the attempts to eliminate this defect are presented as a review paper in a comprehensive manner.

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Section: Solidification Behavior and Crack Sensitivity Of Weld Metalmentioning

confidence: 99%

How to avoid solidification cracking in arc welding of aluminum alloys: a review on weld metal grain refinement approaches

Yolcu,

Kahraman

2023

Mater. Res. Express

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“…Weld solidification cracking, also known as hot cracking, is a defect in fusion welding that occurs in the middle of fusion zone (FZ) during cooling, where the metal experiences strains caused by thermal contraction and solidification shrinkage [3]. Aluminum alloys with high amounts of alloying elements and extended mushy zone, such as Al2024 and Al7075, are more prone to weld solidification cracking [4]. So far, several investigations have been conducted to address this challenge for a variety of processes, including resistance welding [5,6], metal inert gas (MIG) welding [7,8], tungsten inert gas (TIG) welding [7,[9][10][11], laser welding [11,12], and electron beam welding [13,14].…”

Section: Introductionmentioning

confidence: 99%

An adapted approach for solidification crack elimination in Al7075 TIG welding

Abdollahi,

Nganbe,

Kabir

2024

Mater. Res. Express

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Solidification cracking is a long-standing issue in fusion welding of high-strength aluminum alloys like Al7075, imposing limitations on their aerospace and automotive applications. The current study introduces a novel adapted approach in solidification crack elimination by incorporating TiC nanoparticles into the fusion zone using a filler paste as an easier to fabricate alternative to filler metals investigated so far. To assess the weldability of the proposed method, 3-mm thick Al7075 sheets were TIG welded (i) autogenously without any TiC nanoparticles (autogenous), (ii) heterogeneously using 1 vol.% TiC-nanoparticle enhanced Al7075 filler metal (heterogeneous filler metal), and (iii) heterogeneously using an in-house fabricated Al7075 paste containing 1 vol.% TiC nanoparticles (heterogeneous filler paste). Macroscopic analysis of weld specimens proved that both heterogeneous welding approaches effectively eliminated solidification cracks. This was confirmed by Houldcroft solidification susceptibility index deduction tests that demonstrated a strong reduction in solidification crack susceptibly in all heterogeneous joints as compared to the autogenous joint. Microstructural analysis confirmed the transformation from columnar to equiaxed grain morphology in the fusion zone as crucial factor in crack elimination. Overall, the proposed filler paste method represents a highly cost-efficient approach for eliminating solidification cracks in TIG joining of difficult to weld aluminium alloys.

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“…Aluminum alloy is attractive to various fields including rail transit, aerospace, automobile, and other related industries owing to its advantages, such as high strength and excellent corrosion resistance [1][2][3][4]. Laser welding is a precise, non-contact advanced technology and is highly flexible and accurate in joining aluminum alloy materials [5]. However, welding defects, including pores and hot cracks, can easily be formed in welds during aluminum alloy welding.…”

Section: Introductionmentioning

confidence: 99%

“…However, welding defects, including pores and hot cracks, can easily be formed in welds during aluminum alloy welding. Many advanced welding technologies are used to improve the temperature distribution and molten pool dynamic behaviors to suppress the formation of welding defects [5,6]. Welding efficiency is highly related to welding defect formation.…”

Section: Introductionmentioning

confidence: 99%

Numerical Analysis of Molten Pool Dynamic Behaviors during High-Speed Oscillation Laser Welding with Aluminum Alloy

Ai,

Yan,

Han

2024

Metals

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Increased welding speeds are often used to achieve high welding efficiency. However, welding defects, including pores and humps, can easily be formed under high-speed welding conditions. Therefore, a numerical calculation method is proposed to analyze the molten pool dynamic behaviors during high-speed oscillation laser welding with the aluminum alloy. The experiments on high-speed oscillation laser welding are conducted to confirm the simulated results, and both are found to be in good agreement. The distribution characteristics of the temperature field under the condition of a high welding speed are discussed. With the influence of the stirring process from the oscillation laser beam, the temperature gradient is reduced and fluid flow velocity is decreased. The fluid flow in non-oscillation laser welding is more intense than that in oscillation laser welding. It is found that the proposed method can be used to guide the selection of the optimal process parameters for improving welding efficiency and quality in the practical welding process.

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A review: Suppression of the solidification cracks in the laser welding process by controlling the grain structure and chemical compositions

Cited by 18 publications

References 76 publications

How to avoid solidification cracking in arc welding of aluminum alloys: a review on weld metal grain refinement approaches

How to avoid solidification cracking in arc welding of aluminum alloys: a review on weld metal grain refinement approaches

An adapted approach for solidification crack elimination in Al7075 TIG welding

Numerical Analysis of Molten Pool Dynamic Behaviors during High-Speed Oscillation Laser Welding with Aluminum Alloy

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