Remote Laser Welding of Multi-Alloy Aluminum at Close-Edge Position

Understanding novel gap-bridged remote laser welded (RLW) joints for automotive high-rate and temperature applications

“…In contrast, RLW is an autogenous process where no filler wire or shield gas is used. Only a few investigations have been conducted on 6xxx series aluminium alloys to understand the occurrence of hot cracks in overlap joint conditions [24,25]. Albert, et al [22] reported the weldability of steel and aluminium alloys to produce fillet edge weld under different part-to-part gap conditions.…”

High rate and temperature-dependent tensile characterisation with modelling for gap-bridged remote laser welded (RLW) joint using automotive AA5182 alloy

“…To achieve a high welding speed, a fast beam movement was necessary [62] making it difficult to provide effective gas shielding over the large welding area. However, both Müller, et al [35] and Weller, et al [63] have demonstrated that aluminium can be successfully welded using RLW without shielding gas, and laser equipment manufacturers are now developing the RLW process without the provision for shielding gas supply. Additionally, this study has demonstrated that good quality RLW fillet edge welds can be produced without the need for shielding gas.…”

Influence of the solidification path of AlMgSi aluminium alloys on the critical strain rate during remote laser beam welding

“…The alloys Ac-200 RW and Formalex R Remote are especially designed for remote laser beam welding. With their high amount of silicon, the susceptibility to hot cracking is reduced [6,8], which means that no additional filler material is required during welding [7].…”

“…These alloys, belonging to the 6000 series, are well known for their high susceptibility to hot cracking [3][4][5]. Therefore, special AlMgSi alloys are designed to enable remote laser beam welding without hot crack formation [6][7][8]. Hot cracks form and propagate during the solidification process at the trailing end of the moving weld pool, when liquid is still present around the growing dendrites [9,10].…”

“…This ability results from the alloy-specific solidification path, which describes the temperaturedependent solidification progress from liquid to solid in the solidification zone [13]. Alloys designed for remote laser beam welding have a high silicon content, which leads to a high volume fraction of low-melting eutectic phases in the weld [3,6,7]. These low-melting phases ensure that there is still enough residual melt at the end of solidification to compensate for the solidification shrinkage [3].…”