Laser Welding of Dissimilar Aluminium Alloys with Filler Materials

Pinto, Luís Abegão; Quintino, L.; Miranda, Rosa Maria Mendes; Carr, Phill

doi:10.1007/bf03266747

Cited by 27 publications

(11 citation statements)

References 4 publications

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“…There are two main factors responsible for changing the shape and properties of the welds: phenomenological and operational [22]. In the first factor is included the fluctuations of keyhole and melt pool, which can induce a difference of 10% on the total depth of penetration for partially penetrated welds, as previously reported by Suder and Williams [19] and also observed in Fig.…”

Section: Effect Of Interaction Time and Power Factormentioning

confidence: 89%

Fundamental understanding of the interaction of continuous wave laser with aluminium

Coroado

Meco

Williams

et al. 2017

Int J Adv Manuf Technol

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In welding, the depth of penetration, weld profile and the corresponding thermal cycle are the three basic outcomes that a user wishes to control flexibly. In laser welding applications, controlled application of power and energy density is the key to achieve predictable control of these characteristics. Creation of an analytical model is an important step towards understanding the underpinning science of laser metal interaction in controlling the depth, bead geometry and thereby temperature profile of a weld. The "power factor model", which correlates the power applied per unit length to the laser metal interaction time, has been originally developed and validated for mild steel, guides a user on the selection laser system parameters, to achieve specific weld profile. This study is performed to extend the power factor-interaction time model to aluminium alloys by understanding the underpinning laser aluminium interaction parameters in terms of power density, interaction time, specific point energy and their correlation with the weld bead profiles. Although the power factor and interaction time showed a rectangular hyperbolic relationship, as observed in low carbon steel, for a specific weld depth and profile, the absolute magnitude and the characteristic profile of the curve is different due to the intrinsic differences in physical and thermal properties of aluminium as compared to steel. It was shown that identical depth of penetration but different weld metal profile can be obtained for a specific beam diameter for a range of power and travel speed by keeping the energy input per unit length constant.

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Section: Effect Of Interaction Time and Power Factormentioning

confidence: 89%

Fundamental understanding of the interaction of continuous wave laser with aluminium

Coroado

Meco

Williams

et al. 2017

Int J Adv Manuf Technol

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show abstract

“…Therefore, filler materials are used in fusion welding [5]. Pinto et al [6] analysed different weld configurations, aluminium-based filler materials and dissimilar aluminium combination in fusion welding. They found that solidification cracking could be avoided by modifying the weld pool chemistry by using an appropriate filler material and dilution ratios.…”

Section: Introductionmentioning

confidence: 99%

Dilution Ratio and the Resulting Composition Profile in Dissimilar Laser Powder Bed Fusion of AlSi10Mg and Al99.8

Böhm

Werz

Weihe

2020

Metals

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A variant of a hybrid manufacturing process combines the benefits of laser powder bed fusion (LPBF) and conventional manufacturing. Hybrid manufacturing can result in dissimilar material combinations which are prone to process errors. This study is motivated by the future application of a hybrid manufacturing variant and focusses on dissimilar aluminium alloys were hot cracks are the dominant process errors. A theoretical model was derived for the composition profile based on the dilution ratio known from fusion welding. The theory was validated with penetration depth measurements and energy-dispersive X-ray spectroscopy line scans on samples manufactured by LPBF (powder AlSi10Mg, building platform Al99.8 and line energies Pv−1 = 0.26–0.42 J·mm−1). A material combination with a low hot crack susceptibility was chosen to establish the theory. The results suggest that the dilution ratio is dependent on the penetration depth and the layer thickness. The used line energies result in a dilution ratio of 67–86% which results in 2–6 re-melted and mixed layers per added layer. A specific process design metric, the mixture height, is proposed to estimate the spatial effect of the dilution. The results can be used to adjust process parameters to lessen the effect of process errors in dissimilar hybrid manufacturing and increase mechanical performance.

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“…Due to the presence of an aluminium oxide layer, enhanced thermal conductivity and high thermal expansion coefficient [16][17][18], joining aluminium alloys with laser is not trivial. Few investigations are reported on joining of AC-170PX using tactile laser welding where additional filler materials were used to weld, and further, to evaluate weld microstructures and porosity formation [19][20][21]. Basically, these are near-field laser joining under the shielding gas environment, such as argon gas.…”

Section: Introductionmentioning

confidence: 99%

Fiber Laser Based Single Pulse Drilling for Production of Perforated Ti-tanium Sheets for HLFC Structures

2019

JLMN

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Use of lightweight materials to produce automotive body structures is one of the key trends adopted by automotive manufacturers to minimise emission of greenhouse gases, and subsequently, reduction of fuel consumption. Aluminium alloys are one of the promising lightweight materials which are increasingly used for automotive body-in-white structures. Such applications demand both efficient and effective joining/welding methods to produce repeatable, durable and strong joints without significant alteration of material properties. Remote laser welding (RLW) is an emerging joining technology and increasingly being used to produce lightweight joints as it satisfies the demand for high production throughput at low cost. This paper investigates the effects of process parameters when seam tracking remote laser welding is used to create an autogenous fillet edge weld of automotive grade aluminum alloy (AC-170PX) in lap configuration without shielding gas. The effects of laser power and welding speed on the key geometric features are reported together with details of the weld microstructure. Joint strength is evaluated by performing a lap shear test. It is found that the laser power and welding speed have dominant influence on key geometric features and subsequently on the lap shear strength. Relatively larger grain size in the fusion zone reduces the microhardness by up to 20% in comparison with the base material.

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Laser Welding of Dissimilar Aluminium Alloys with Filler Materials

Cited by 27 publications

References 4 publications

Fundamental understanding of the interaction of continuous wave laser with aluminium

Fundamental understanding of the interaction of continuous wave laser with aluminium

Dilution Ratio and the Resulting Composition Profile in Dissimilar Laser Powder Bed Fusion of AlSi10Mg and Al99.8

Fiber Laser Based Single Pulse Drilling for Production of Perforated Ti-tanium Sheets for HLFC Structures

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