Understanding the Effect of Heat Input and Sheet Gap on Porosity Formation in Fillet Edge and Flange Couch Laser Welding of AC-170PX Aluminum Alloy for Automotive Component Manufacture

2015 ◽  
Vol 137 (2) ◽  
Author(s):  
A. W. Alshaer ◽  
L. Li ◽  
A. Mistry
Keyword(s):  
Laser Welding ◽  
Heat Input ◽  
Filler Wire ◽  
Porosity Formation ◽  
Noticeable Effect ◽  
Automotive Manufacturing ◽  
Microstructure Characteristics ◽  
Joint Geometry ◽  
Manufacturing Applications ◽  
Characteristics Of Porosity

An investigation is reported on the characteristics of porosity formation in high power disk laser welding of AC-170PX (AA6014) alloy sheets (coated with titanium and zirconium) in two weld joint configurations: fillet edge and flange couch with AA4043 filler wire for potential automotive manufacturing applications. Porosity, macro- and microstructure characteristics, tensile strengths, microhardness, and joint geometry were investigated. It has been found that an increase in heat input and welding speed generates more porosity in both types of joints. The introduction of a 0.2 mm gap reduces porosity significantly in the fillet edge joints but it does not have noticeable effect on the flange couch joints. The mechanism of the porosity formation is discussed.

Effect of filler wire properties on porosity formation in laser welding of AC-170PX aluminium alloy for lightweight automotive component manufacture

2015 ◽  
Vol 231 (6) ◽  
pp. 994-1006 ◽  
Author(s):  
Ahmad Wael AlShaer ◽  
Lin Li ◽  
Anil Mistry
Keyword(s):  
Laser Welding ◽  
Aluminium Alloy ◽  
High Power ◽  
Weld Joint ◽  
Filler Wire ◽  
Porosity Formation ◽  
Automotive Component ◽  
Joint Geometry ◽  
Mn Content ◽  
Characteristics Of Porosity

AC-170PX (AA6014) alloys are typically used in lightweight automobile vehicles. Laser welding can be a viable tool for the assembly of components. However, porosity is often generated during aluminium welding. In this article, an investigation is reported on the characteristics of porosity formation in high-power disc laser welding of AC-170PX aluminium alloy sheets in two weld joint configurations: fillet edge and flange couch with three different filler wires of 4xxx, 3xxx and 5xxx aluminium series for each joint. Porosity, microstructures, tensile strengths and joint geometry were investigated. It has been found that the use of filler wires with higher Mg and Mn content such as AA5083 and AA3004 leads to a significant reduction in porosity to less than 1.5% in both types of joints compared with up to 80% porosity with the silicon-rich AA4043 wire. The mechanism that led to this improvement is discussed.

scholarly journals Effect of Heat Input During Disk Laser Bead-On-Plate Welding of Thermomechanically Rolled Steel on Penetration Characteristics and Porosity Formation in the Weld Metal

2016 ◽  
Vol 61 (1) ◽  
pp. 93-102 ◽  
Author(s):  
A. Lisiecki
Keyword(s):  
Laser Welding ◽  
Heat Input ◽  
Welding Parameters ◽  
Depth Of Penetration ◽  
Porosity Formation ◽  
Disk Laser ◽  
Full Penetration ◽  
Wide Range ◽  
Weld Porosity ◽  
The Relationship

The paper presents a detailed analysis of the influence of heat input during laser bead-on-plate welding of 5.0 mm thick plates of S700MC steel by modern Disk laser on the mechanism of steel penetration, shape and depth of penetration, and also on tendency to weld porosity formation. Based on the investigations performed in a wide range of laser welding parameters the relationship between laser power and welding speed, thus heat input, required for full penetration was determined. Additionally the relationship between the laser welding parameters and weld quality was determined.

scholarly journals Development of laser welding of high strength aluminium alloy 2024-T4 with controlled thermal cycle

2020 ◽  
Vol 326 ◽  
pp. 08005
Author(s):  
Mete Demirorer ◽  
Wojciech Suder ◽  
Supriyo Ganguly ◽  
Simon Hogg ◽  
Hassam Naeem
Keyword(s):  
Laser Beam ◽  
Laser Welding ◽  
Heat Input ◽  
Thermal Cycle ◽  
Laser Beam Welding ◽  
Base Material ◽  
High Strength ◽  
Cooling Rates ◽  
Aa 2024 ◽  
Welding Processes

An innovative process design, to avoid thermal degradation during autogenous fusion welding of high strength AA 2024-T4 alloy, based on laser beam welding, is being developed. A series of instrumented laser welds in 2 mm thick AA 2024-T4 alloys were made with different processing conditions resulting in different thermal profiles and cooling rates. The welds were examined under SEM, TEM and LOM, and subjected to micro-hardness examination. This allowed us to understand the influence of cooling rate, peak temperature, and thermal cycle on the growth of precipitates, and related degradation in the weld and heat affected area, evident as softening. Although laser beam welding allows significant reduction of heat input, and higher cooling rates, as compared to other high heat input welding processes, this was found insufficient to completely supress coarsening of precipitate in HAZ. To understand the required range of thermal cycles, additional dilatometry tests were carried out using the same base material to understand the time-temperature relationship of precipitate formation. The results were used to design a novel laser welding process with enhanced cooling, such as with copper backing bar and cryogenic cooling.

Determination of Heat Input in Tungsten Inert Gas and Laser Welding of Type Optim 960 QC Structural Steel Using Adams’ Equation for 2-D Heat Distribution

2017 ◽  
Vol 750 ◽  
pp. 45-52
Author(s):  
Sveto Cvetkovski
Keyword(s):  
Laser Welding ◽  
Heat Input ◽  
Arc Welding ◽  
Research Work ◽  
Laser Beam Welding ◽  
Peak Temperature ◽  
Efficiency Coefficient ◽  
Zone Recrystallization ◽  
Welding Processes

The heat input during conventional arc welding processes can be readily calculated knowing the power taken from the power source. The efficiency coefficient can be taken from the appropriate literature standards. Here, the intention of the performed research work was to develop a procedure for determination of heat input in arc and laser welding processes implementing Adams equation - modified Rykalin equation for two dimensional heat distributions (2-D). To realize this idea, it is necessary to determine two characteristic temperatures points in the HAZ with known peak temperature, and to determine distance between them. Implementing measured values for distance in Adams’ equation, heat input in arc welding can be directly determined in arc welded joints.In laser beam welding, the absorption of the beam in the metal is not known, so that the welding heat input cannot be calculated directly, and direct implementation of Adam’s equation is not possible i.e. absorption coefficient has to be determined first, and after that calculation of heat input is possible.The peak temperatures corresponding to specific microstructures can be obtained by performing welding simulation, by the Gleeble 1500 simulator in our case. As one of the peak temperatures, the melting temperature can be used corresponding to the fusion line, so that at least one characteristic peak temperature such as coarse grain zone, fine grin zone, intercritical zone, recrystallization, has to be determined by the simulation.Performed research showed that obtained values for heat input using Adam’s equation correspond pretty well with standard equation for heat input in arc welding.

Advances in joining technologies for the innovation of 21st century lightweight aluminium-CFRP hybrid structures

2022 ◽  
pp. 095440892110730
Author(s):  
Renangi Sandeep ◽  
Arivazhagan Natarajan
Keyword(s):  
Shear Strength ◽  
Laser Welding ◽  
Heat Input ◽  
Mechanical Performance ◽  
Current Knowledge ◽  
Ultrasonic Welding ◽  
Hybrid Structures ◽  
Joint Shear Strength ◽  
Hybrid Joints ◽  
Welding Processes

In the twenty-first century, the application of carbon fiber reinforced polymer (CFRP) materials in the vehicle industry are growing rapidly due to lightweight, high specific strength, and elasticity. In the automobile and aerospace industries, CFRP needs to be joined with metals to build complete structures. The demand for hybrid structures has prompted research into the combination of CFRP and metals in manufacturing. Aluminium and CFRP structures combine the mechanical properties of aluminium with the superior physical and chemical properties of CFRP. However, joining dissimilar materials is often challenging to achieve. Various joining technologies are developed to produce hybrid joints of CFRP, and aluminium alloys include conventional adhesives, mechanical and thermal joining technologies. In this review article, an extensive review was carried out on the thermal joining technologies include laser welding, friction-based welding technologies, ultrasonic welding, and induction welding processes. The article primarily focused on the current knowledge and process development of these technologies in fabricating dissimilar aluminium and CFRP structures. Besides, according to Industry 4.0 requirements, additive manufacturing-based techniques to fabricate hybrid structures are presented. Finally, this article also addressed the various improvements for the future development of these joining technologies. Ultrasonic welding yields the maximum shear strength among the various hybrid joining technologies due to lower heat input. On the other hand, laser welding produces higher heat input, which deteriorates the mechanical performance of the hybrid joints. Surface pretreatments on material surfaces prior to joining showed a significant effect on joint shear strength. Surface modification using anodizing is considered an optimal method to improve wettability, increasing mechanical interlocking phenomena.

Optimization of weld bead geometry in laser welding with filler wire process using Taguchi’s approach

2012 ◽  
Vol 44 (7) ◽  
pp. 2020-2025 ◽  
Author(s):  
Yang dongxia ◽  
Li xiaoyan ◽  
He dingyong ◽  
Nie zuoren ◽  
Huang hui
Keyword(s):  
Laser Welding ◽  
Weld Bead ◽  
Bead Geometry ◽  
Filler Wire ◽  
Weld Bead Geometry

scholarly journals Dendritic Boundary Corrosion of AA2198 Weld Using Fiber Laser Welding with Al–Cu Filler Wire

2017 ◽  
Vol 31 (7) ◽  
pp. 735-741 ◽  
Author(s):  
Jun-Xia Lu ◽  
Ling Chang ◽  
Shi-Kai Wu ◽  
Shi-Kun Yin
Keyword(s):  
Laser Welding ◽  
Fiber Laser ◽  
Filler Wire ◽  
Fiber Laser Welding
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