Trend and innovations in laser beam welding of wrought aluminum alloys

Ojo, Olatunji Oladimeji; Taban, Emel

doi:10.1007/s40194-016-0317-9

Cited by 64 publications

(19 citation statements)

References 142 publications

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“…Friction stir spot welding (FSSW) is an eco-friendly or green solid-state joining process that has the capacity of eliminating the conventional fusion welding problems of low-density alloys like aluminium, copper, titanium, magnesium and even metal matrix composites [1]. As such, the predominant weldability problems of fusion welding of aluminium alloys, such as thermal shrinkages and distortion, weld porosity or internal voids [2][3][4][5], alloy segregation, formation of brittle inter-dendritic structure [6], microfissuring and hot cracking [4,7], evaporation of strengthening or alloying elements [8], solidification stress corrosion and pitting corrosion, can be efficiently reduced or eliminated with the application of FSSW process. Consequently, FSSW has become a desirable and widely accepted fabrication technology that has found its application in industries like automotive, aerospace and aviation, and high-speed train manufacturing [2].…”

Section: Introductionmentioning

confidence: 99%

Hybrid multi-response optimization of friction stir spot welds: failure load, effective bonded size and flash volume as responses

Ojo

Taban

2018

Sādhanā

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Friction stir spot welding (FSSW) is a multi-input multi-response process. Effective multi-response optimization of welds is desirable to create welds with a balance of quality responses. In order to eliminate the subjectivity (uncertainty and engineering judgment) with the existing multi-response Taguchi-based Grey relational analysis, principal component analysis (PCA) was integrated into it. The PCA helps in determining the effective optimal weighting values required for the estimation of Grey relational grade (GRG). As a result, tool rotational speed, plunge depth and dwell time were employed as input parameters while failure load (FL), expelled flash volume (EFV) and effective bonded size (EBS) of conical pin friction stir spot-welded joint of AA2219-O alloy were the chosen output responses. EFV was minimized while FL and EBS of the joints were maximized using this hybrid multi-response approach. From the analysis of variance of GRG and its response graphs, the significant parameters and their levels were obtained. Experimental results confirmed the effectiveness and robustness of this method. In addition, three critical zones were observed on the fracture surfaces of joints, namely, tool impelled unbonded zone, partially bonded zone and effective bonded/nugget zone. The weld nugget failed by circumferential nugget shear mode.

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Section: Introductionmentioning

confidence: 99%

Hybrid multi-response optimization of friction stir spot welds: failure load, effective bonded size and flash volume as responses

Ojo

Taban

2018

Sādhanā

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“…One of the heat sources is laser, which is now widely used for welding and material processing [11][12][13][14] and can potentially be used to weld a container. Steels with BCC [15][16][17] and FCC [18][19][20] crystallographic space groups, aluminum alloys [21], titanium alloys [22], nickel alloys [23], plastics [24], and composites [25] can be laser beam welded. These joints are characterized by a narrow weld and a heat-affected zone with mechanical properties similar to those of joints made with conventional electric arc processes [26] and often exceeding them.…”

Section: Requirements For the Ferrofluid Containermentioning

confidence: 99%

Laser welding of austenitic ferrofluid container for the KRAKsat satellite

Janiczak

Pańcikiewicz

2021

Weld World

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The production of a ferrofluid container, intended for use in the KRAKsat (CubeSat type) satellite in space conditions, is presented. Mechanized laser beam welding for AISI 316L stainless steel test joint and container prototype was developed and tested. The welded test joints were examined by non-destructive visual, penetration and radiographic testing and destructive testing by macro- and microscopic examination, static tensile test, static bending test, and hardness measurements. The welded container prototype was examined by leak test, temperature-vacuum test and vibration test. Test joints’ evaluation showed a proper selection of welding parameters and expected quality of joints. Austenitic microstructure with small δ-ferrite content in base materials, heat-affected zones, and welds guarantees sufficient mechanical properties for this part geometry. The tensile strength range of test joints was 687–729 MPa, hardness range was 140–200 HV3, and the bending angle was 180°. Welding of the prototype container and testing of tightness, resistance to temperature changes, and vibration were successful. Compliance with flywheel design and manufacturing requirements will enable the launch of a research satellite into orbit with such a wheel.

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“…When laser welding thick aluminum alloy structures, the keyhole-welding mode requiring a high-power laser source should be adopted to obtain high penetration depths. However, some critical issues usually arise during the welding process: (I) high energy consumption—the energy density (ratio of the laser power to the beam spot area) for iron-based materials in the keyhole-welding mode is approximately 10 6 W/cm 2 , while the value for aluminum alloys is at least 1.5 × 10 6 W/cm 2 and even 2 × 10 6 W/cm 2 , because aluminum alloys possess high laser radiation reflection and thermal conductivity [ 85 , 86 ]; (II) keyhole-induced porosity—the low-viscosity aluminum alloys cause the keyhole to become unstable and easily collapse, resulting in the entrapment of the gas bubbles during the cooling, which dramatically reduces the mechanical properties of the joint [ 87 , 88 ]; (III) low gap bridging ability and high requirement in positioning—laser welding with a high welding speedand a small focusing point [ 89 , 90 , 91 ].…”

Section: Low-heat-input Weldingmentioning

confidence: 99%

Review of Techniques for Improvement of Softening Behavior of Age-Hardening Aluminum Alloy Welded Joints

et al. 2021

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The softening phenomenon of age-hardening aluminum alloy-welded joints is severe during conventional fusion welding, which increases the likelihood of stress and strain concentration in the joint during the period of service, significantly reduces the mechanical properties compared to the base metal, and represents an obstacle to the exploration of the potential structural performance. This review paper focuses on an overview of the softening phenomenon. Firstly, the welding softening mechanism and the characteristics of age-hardening aluminum alloys are clarified. Secondly, the current main research methods that can effectively improve joint softening are summarized into three categories: low-heat-input welding, externally assisted cooling during welding, and post-weld treatment. The strengthening mechanism and performance change rule of age-hardening aluminum alloy joints are systematically analyzed. Finally, this paper considers the future development trends of further research on joint softening, and it is expected that interest in this topic will increase.

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Trend and innovations in laser beam welding of wrought aluminum alloys

Cited by 64 publications

References 142 publications

Hybrid multi-response optimization of friction stir spot welds: failure load, effective bonded size and flash volume as responses

Hybrid multi-response optimization of friction stir spot welds: failure load, effective bonded size and flash volume as responses

Laser welding of austenitic ferrofluid container for the KRAKsat satellite

Review of Techniques for Improvement of Softening Behavior of Age-Hardening Aluminum Alloy Welded Joints

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