Correlation between gas-dynamic behaviour of a vapour plume and oscillation of keyhole size during laser welding of 5083 Al-alloy

Huang, Yicheng; Shen, Chen; Ji, Xiangru; Li, Fang; Zhang, Yuelong; Hua, Xueming

doi:10.1016/j.jmatprotec.2020.116721

Cited by 29 publications

(6 citation statements)

References 22 publications

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“…During vaporisation, the three orders of magnitude increase in volume of the metallic phases creates a large velocity normal to the fluid interface (captured through the v Á term in the continuity equation); this high velocity ejects the vapour plume, simultaneously creating a recoil effect on the liquid metal that stabilises the thermo-capillary against collapse. The predicted vapour plume ejection velocity is in good agreement with experimental and numerical studies in the literature 38,42,43 . The maximum velocity recorded in the present simulation was 124 m s −1 .…”

Section: Discussionsupporting

confidence: 87%

A thermal fluid dynamics framework applied to multi-component substrates experiencing fusion and vaporisation state transitions

et al. 2020

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The fluid dynamics of multi-component alloy systems subjected to high energy density sources of heat largely determines the local composition, microstructure, and material properties. In this work a multi-component thermal fluid dynamics framework is presented for the prediction of alloy system development due to melting, vaporisation, condensation and solidification phenomena. A volume dilation term is introduced into the continuity equation to account for the density jump between liquid and vapour species, conserving mass through vaporisation and condensation state changes. Mass diffusion, surface tension, the temperature dependence of surface tension, buoyancy terms and latent heat effects are incorporated. The framework is applied to describe binary vapour collapse into a heterogeneous binary liquid, and a high energy density power beam joining application; where a rigorous mathematical description of preferential element evaporation is presented.

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Section: Discussionsupporting

confidence: 87%

A thermal fluid dynamics framework applied to multi-component substrates experiencing fusion and vaporisation state transitions

et al. 2020

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“…As a result of their research into the correlations of the factors relating to the formation of pores, it was, found that formation of pores is not only caused by hydrogen and magnesium metal vapor, but is also associated with the segregation of magnesium into the solute band. Huang et al [34] found that the interaction between the vapor plume and the keyhole is considered to induce the oscillation of keyhole and vapor plume. Depending on the alloying elements, the 5xxx series alloys can form different phases [35,36].…”

Section: Introductionmentioning

confidence: 99%

The Effect of Process Parameters on the Microstructure and Mechanical Properties of AW5083 Aluminum Laser Weld Joints

Vyskoč

Dománková

Jurči

et al. 2020

Metals

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In this article, the effect of process parameters on the microstructure and mechanical properties of AW5083 aluminum alloy weld joints welded by a disk laser were studied. Butt welds were produced using 5087 (AlMg4.5MnZr) filler wire, with a diameter of 1.2 mm, and were protected from the ambient atmosphere by a mixture of argon and 30 vol.% of helium (Aluline He30). The widest weld joint (4.69 mm) and the highest tensile strength (309 MPa) were observed when a 30 L/min shielding gas flow rate was used. Conversely, the narrowest weld joint (4.15 mm) and the lowest tensile strength (160 MPa) were found when no shielding gas was used. The lowest average microhardness (55.4 HV0.1) was recorded when a 30 L/min shielding gas flow rate was used. The highest average microhardness (63.9 HV0.1) was observed when no shielding gas was used. In addition to the intermetallic compounds, β-Al3Mg2 and γ-Al12Mg17, in the inter-dendritic areas of the fusion zone (FZ), Al49Mg32, which has an irregular shape, was recorded. The application of the filler wire, which contains zirconium, resulted in grain refinement in the fusion zone. The protected weld joint was characterized by a ductile fracture in the base material (BM). A brittle fracture of the unshielded weld joint was caused by the presence of Al2O3 particles. The research results show that we achieved the optimal welding parameters, because no cracks and pores were present in the shielded weld metal (WM).

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“…The oscillatory welding pattern is a newly developed technique that is used for aluminum welding, mostly for gap-bridging and increasing the tolerance of the laser welding process. In [17] and [21], the oscillation pattern was adopted for controlling the melt pool morphology. It induces an elliptical weld pool instead of a teardrop and leads to a fine weld structure that withstands shrinkage load better and thus prevents crack initiation [22].…”

Section: Highlightsmentioning

confidence: 99%

Overlap laser welding of 5052-H36 aluminum alloy: experimental investigation of process parameters and mechanical designs

Idriss

Mirakhorli

Desrochers

et al. 2022

Int J Adv Manuf Technol

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In this study, the laser welding process is used to join 1.6-mm-thick AA5052-H36 sheets in an overlap joint configuration. Both pulse and oscillation laser beam welding were investigated for the first laser pass. Oscillation beam laser welding in continuous-wave mode show more stable and sound weld with no porosity defects compare to pulse wave (PW) mode. The adopted welding power, speed, frequency, and defocus are 8 kW, 6.5 m/min, 150 Hz, and + 8 mm, respectively. The obtained stitch welds are defects free (blowholes, micro-cracks, or porosities). A circular oscillation ramp-up/ramp-down PW mode is adopted for a second laser surface re-melting (LSR) pass. The corresponding welding power, speed, frequency, and defocus are 5 kW, 2.5 m/min, 500 Hz, and + 15 mm, respectively. Shear tests are then performed to evaluate the mechanical properties of single lap joints (SLJ) for different stitch weld shapes, 2 gap tolerances (0 and 0.5 mm), as well as with/without LSR pass. The best tests’ reproducibility and highest dissipated energies (~ + 42% when compared to the perpendicular direction) are obtained when the stitch weld direction corresponds to the loading direction. The second LSR pass provides more aesthetic joints with higher shear resistance (~ + 1% to + 3%) due to a decrease in the weld surface underfill and undercut imperfections of the stitch weld. The part-to-part gap leads to higher shear resistance (~ + 20%) owing to 2 main reasons: larger welding surfaces at the joint interface and higher hardness of the fusion zone. These findings are of great value for including laser welding technology in the automotive and surface transportation industries. Graphic abstract

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Correlation between gas-dynamic behaviour of a vapour plume and oscillation of keyhole size during laser welding of 5083 Al-alloy

Cited by 29 publications

References 22 publications

A thermal fluid dynamics framework applied to multi-component substrates experiencing fusion and vaporisation state transitions

A thermal fluid dynamics framework applied to multi-component substrates experiencing fusion and vaporisation state transitions

The Effect of Process Parameters on the Microstructure and Mechanical Properties of AW5083 Aluminum Laser Weld Joints

Overlap laser welding of 5052-H36 aluminum alloy: experimental investigation of process parameters and mechanical designs

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