The Effects of Laser Welding Direction on Joint Quality for Non-Uniform Part-to-Part Gaps

Oh, Rocku; Kim, Duck Young; Ceglarek, Darek

doi:10.3390/met6080184

Cited by 5 publications

(4 citation statements)

References 14 publications

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“…Thus, a better weld pool quality is obtained leading to a higher shear tensile strength (Fig. 11) [23]. Nevertheless, the second LSR pass leads to an improvement in the weld quality in the FZ/HAZ interface (Fig.…”

Section: Second Lsr Passmentioning

confidence: 98%

“…In addition to process parameters, the mechanical behavior of a laser-welded joint is also influenced by geometrical and manufacturing parameters such as part-to-part gap, second laser surface remelting (LSR) pass, and stitch weld shape. For a reliable welding joint, the authors in [23] recommended a part-to-part gap not exceeding 0.3 mm in overlap joint with an upper sheet thickness of 1.4 mm. However, this value can hardly be respected in an industrial environment.…”

Section: Highlightsmentioning

confidence: 99%

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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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Section: Second Lsr Passmentioning

confidence: 98%

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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“…To shield the welding zone, helium (5.0) was used, with the flow rate equal to 20 l/min conveyed coaxially. The laser beam was focused on the surface of the top plate in a PA (flat) position and the welding trajectory was established based on the boundary conditions of the simulation [ 39 ]. Using single pass welding, lap joints in two configurations were obtained: the 1st with the low-carbon steel placed on the top (and the 316L sheet at the bottom), and the 2nd with the 316L steel placed on the top (and the S355J2 sheet at the bottom).…”

Section: Materials and Experimental Designmentioning

confidence: 99%

Numerical and Metallurgical Analysis of Laser Welded, Sealed Lap Joints of S355J2 and 316L Steels under Different Configurations

et al. 2020

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This paper presents the results of laser welding of dissimilar joints, where low-carbon and stainless steels were welded inthe lap joint configuration. Performed welding of austenitic and ferritic-pearlitic steels included a sealed joint, where only partial penetration of lower material was obtained.The authors presented acomparative study of the joints under different configurations. The welding parameters for the assumed penetration were estimated via anumericalsimulation. Moreover, a stress–strain analysis was performed based on theestablished model. Numerical analysis showed significant differences in joint properties, therefore, further study was conducted. Investigation of the fusion mechanism in the obtained joints wascarried out using electron dispersive spectroscopy (EDS) and metallurgical analysis. The study of the lap joint under different configurations showed considerable dissimilarities in stress–strain distribution and relevant differences in the fusion zone structure. The results showed advantages of using stainless steel as the upper material of a microstructure, and uniform chemical element distribution and stress analysis is considered.

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“…Oh et al, assuming non-uniform part-to-part gaps, have examined the effects of welding direction on the quality of the joint of galvanized steel sheets SGARC440 (lower part) and SGAFC590DP (upper part), examined using 2-kW fiber and 6.6-kW disk laser welding systems [36].…”

Section: The Present Issuementioning

confidence: 99%

Advances in Welding Metal Alloys, Dissimilar Metals and Additively Manufactured Parts

Casalino

2017

Metals

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Nowadays, strong, light-weight, multi-functional, high performing products are key for achieving success in the worldwide markets. Meeting those requirements calls for enabling technologies that lead to innovative and sustainable manufacturing [1].A joint technique is one or a combination of the available mechanical, chemical, thermal processes to create a bond between materials with a number of combinations and geometries. Welding processes of metal alloys use a thermal energy source that can either melt materials of similar compositions and melting points or produce coalescence at temperatures essentially below the melting point of the base materials being joined. Such well-known welding processes include thermal fusion joining processes and solid-state joining processes; the latter are gaining renewed interest.Among the thermal fusion joining processes, the most common process is electric arc welding. Several methods use the electric arc approach for fusion welding of steel [2], aluminum [3], titanium [4] and magnesium alloys [5]. The selection of filler material is critical for the quality of the dissimilar metal welds [6].Laser beam and electron beam welding are high-energy beam welding methods that can operate in either melt-in/conduction or keyhole mode. In the latter mode, the laser beam is highly effective at welding metals. Similar and dissimilar weld can be produced for appliance, automotive, and aerospace applications [7][8][9].Brazing and soldering involve a filler material, heated to its melting temperature, and applied between the mating parts, which do not melt. Recently, laser autogenous brazing has enabled the selective use of the unique properties exhibited by biocompatible materials such as stainless steel and shape memory materials, such as NiTi, to tailor the properties of implantable medical devices [10]. Important mid-temperature thermoelectric materials such as Pb Te-based alloys can be successfully brazed to form a thermoelectric module [11].Resistance spot welding, which dominates the steel body-in-white production, involves a strong current through the metal combination that heats up and finally melts the metals at localized points. A force is applied before, during and after the application of the current to confine the contact area at the weld interfaces and, in some applications, to forge the workpieces. Similar [12] and dissimilar [13] weld can be easily produced.Within the solid-state joining process, friction stir welding has gained a prominent position. Invented in 1991, it uses a non-consumable tool to join two facing workpieces without melting the workpiece material. Heat is generated by friction between the rotating tool and the workpiece material. This welding method has great capability at welding lightweight [14] and dissimilar weld [15]. Otherwise, friction welding is a process where the two pieces are moved relatively by means of an upsetting force. The relative motion heats the two pieces to a plastic-state. Two friction welding processes are available: linear friction...

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The Effects of Laser Welding Direction on Joint Quality for Non-Uniform Part-to-Part Gaps

Cited by 5 publications

References 14 publications

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

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

Numerical and Metallurgical Analysis of Laser Welded, Sealed Lap Joints of S355J2 and 316L Steels under Different Configurations

Advances in Welding Metal Alloys, Dissimilar Metals and Additively Manufactured Parts

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