Investigation of metal mixing in laser keyhole welding of dissimilar metals

Huang, Wenkang; Wang, Hongliang; Rinker, Teresa J.; Tan, Wenda

doi:10.1016/j.matdes.2020.109056

Cited by 101 publications

(33 citation statements)

References 58 publications

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“…The reductions in penetration depth for the CAA and ACA lap con gurations were greater than that for the ACC con guration. This is because when the Cu layer was placed closer to the focused laser beam, the heat input quickly dissipated to the surroundings [25] due to the high melting point and thermal diffusivity of copper. Another reason for this difference was the fact that lasers with wavelengths greater than 1 µm exhibit a low absorption rate for copper [26].…”

Section: Effect Of Lap Con Guration On Penetration Depthmentioning

confidence: 99%

“…Minimization of IMPs can be accomplished by suppressing the intermixture of metals and reducing the processing time to avoid diffusion. Huang et al [25] demonstrated the concentration behavior of Cu in a Cu (top)−Al (bottom) dissimilar material joint via a multi-physics numerical model and ex situ element mapping. They proved that the concentration of Cu in the top region of the molten pool was over 50 wt% under high-speed welding conditions as a result of the upward ow in the molten pool that is driven by the recoil pressure.…”

Section: Introductionmentioning

confidence: 99%

“…They proved that the concentration of Cu in the top region of the molten pool was over 50 wt% under high-speed welding conditions as a result of the upward ow in the molten pool that is driven by the recoil pressure. The element mixing process in laser keyhole welding is affected by the laser power, welding speed, and heat input [25]. This indicates that proper welding parameters are required to suppress the formation of IMPs to obtain desirable joint characteristics, such as ductility and toughness.…”

Section: Introductionmentioning

confidence: 99%

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Effects of Lap Configuration on Mechanical Properties and Composition Distribution of Three-layer Overlapped Laser Weldments on Al/Cu Dissimilar Materials

Shin

Kang

2022

Preprint

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Battery cells are connected via bus-bars to meet performance requirements, such as power and capacity, and multiple layers of dissimilar materials functioning as anodes, cathodes, or bus-bars are overlapped and welded together. In laser welding, the formation of brittle intermetallic phases in the weld joint is inevitable and, in turn, deteriorates the mechanical properties. To obtain the desirable joint performance, appropriate welding parameters to avoid intermetallic phase formations and joint designs to release stress concentrations must be obtained. This study investigates the effects of lap configurations and process parameters on the tensile-shear load, T-peel load, and composition distribution when multi-layered joints of dissimilar materials are produced by laser welding. Two layers of 0.4 mm Al sheets were welded with a single 0.2 mm Cu sheet, which was emulated using electric vehicle battery interconnects. The results show that the penetration depth varied in accordance with the lap configuration even under the same heat input condition. The lap configuration and welding parameters influenced the composition distribution of the welds, as they altered the solidification rate, number of Cu/Al contact interfaces, and location of the high-density material. The failure load of the T-peel specimens was always lower than that of the tensile-shear specimens except for the Cu−Al−Al lap configuration. The T-peel load of the Cu−Al−Al lap configuration was similar to that of the tensile-shear load. When the stress-concentrated joint was homogeneous, it was more robust.

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Section: Effect Of Lap Con Guration On Penetration Depthmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Effects of Lap Configuration on Mechanical Properties and Composition Distribution of Three-layer Overlapped Laser Weldments on Al/Cu Dissimilar Materials

Shin

Kang

2022

Preprint

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“…In the manufacturing of the body of high-speed trains and urban rail vehicles, the overall weight and strength of the divided side walls determine that the welded joints are of unequal thickness, the commonly used welding method is the resistance spot welding of the stainless steel lap joint, because the welding mechanism is simple and easy to automate in robot production [ 2 ]. However, many studies [ 3 , 4 , 5 , 6 ] have shown that laser keyhole welding has more advantages in the welding of overlap joints of plants, such as localized heating, small welding deformation, and high penetration depth. Laser keyhole welding has gradually replaced resistance spot welding in automobile and rail vehicle manufacturing.…”

Section: Introductionmentioning

confidence: 99%

Influence of Assembly Gap Size on the Structure and Properties of SUS301L Stainless Steel Laser Welded Lap Joint

Wang

et al. 2021

Materials

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The microstructure and properties of laser welding lap joints with different assembly gap sizes are experimentally investigated. The laser weld joint is composed of γ-austenite and δ-ferrite, and the strip ferrite phase is mainly distributed at the austenite grain boundary. The weld metal presents the austenitic-ferritic (AF) solidification mode. When there is a gap between the two plates, a triangular region composed of similar equiaxed crystals can be found, and the size of the cellular crystals in this region decreases significantly. When the assembly gap size increases from 0.1 mm to 0.4 mm, the weld penetration state of the joint changes from full penetration to semi-penetration, and the surface collapse increases. The excessive size of the gap leads to a decrease in the tensile-shear force and fatigue strength of laser welded joints. In order to ensure that the surface morphology and properties of the welded joint meet the quality standard and requirement, the assembly gap should be less than 0.1mm.

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“…Huang et al [18] proposed a multi-physics numerical model for investigating the physics of laser keyhole welding of dissimilar metals between aluminum and copper, in which heat transfer, fluid flow, and metal mixing in the molten pool were taken into account. It was shown that high laser power increased both recoil pressure and Marangoni stress that forced more copper migrated upward and mixed with aluminum.…”

Section: Introductionmentioning

confidence: 99%

Experimental investigations and FE modeling considering microstructural inhomogeneity of laser welded steel-aluminum joints

Kimthong

Wattanapornphan

Phongphisutthinan

et al. 2021

Archiv.Civ.Mech.Eng

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Progresses in fusion joining between aluminum alloys with steel were limited due to its complex metallurgical reactions between liquid steel and aluminum. This work provided an insight into effects of homogeneous and inhomogeneous fusion zone of laser welded steel-aluminum joints. Detailed metallographic and chemical composition analyses of the fusion zone were first presented and discussed. An indentation reverse method was developed for predicting local stress-strain behaviors of the fusion zones. Then, FE simulations of lap shear test for laser welded steel-aluminum joint were performed, in which individual properties of the weld zone were given. The cohesive zone model (CZM) based on maximum strength was applied for representing local damage evolution of intermetallic layer along the interface in welded samples. Cross tension and double cantilever beam (DCB) tests were conducted for determining mode I bonding strength and fracture energy of the CZM. The peak forces of welded steel-aluminum joint samples using different welding speeds were predicted. The numerical results showed satisfactory agreement with experimentally obtained values. In addition, fracture behaviors of different welded samples were evaluated with regard to developed microstructural characteristics. It was found that the dominant local failure mechanism of laser welded steel-aluminum joints was strongly governed by the inhomogeneity of chemical and mechanical properties of their fusion zones that could be precisely described by the proposed model.

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Investigation of metal mixing in laser keyhole welding of dissimilar metals

Cited by 101 publications

References 58 publications

Effects of Lap Configuration on Mechanical Properties and Composition Distribution of Three-layer Overlapped Laser Weldments on Al/Cu Dissimilar Materials

Effects of Lap Configuration on Mechanical Properties and Composition Distribution of Three-layer Overlapped Laser Weldments on Al/Cu Dissimilar Materials

Influence of Assembly Gap Size on the Structure and Properties of SUS301L Stainless Steel Laser Welded Lap Joint

Experimental investigations and FE modeling considering microstructural inhomogeneity of laser welded steel-aluminum joints

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