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Laser Welding of Dissimilar Metal Joint of 6061 Al Alloy and Al Matrix Composite
摘要： In this paper, dissimilar metal joints of 6061 aluminum alloy and aluminum matrix composite material are investigated by laser welding. TiB2 particles were added into the lap joint. The welding process, microstructure, and the corrosion properties of welding joints are examined. The results demonstrate that the selected optimization process parameters are laser power 6 kW, welding speed 0.6 mm/s, pulse width 11.5 ms, and laser frequency 4.5 Hz. There are a few obvious pores in the molten pool. Al2Ti, Fe2Si, and Al0.5Fe3Si0.5 are present in the microstructure. During the welding process, some TiB2 particles are decomposed and reacted with molten Al. Other TiB2 particles are nucleated and solidi?ed, and the excess TiB2 particles are pushed to the grain boundaries by molten Al. TiB2 particles are wetted well by molten matrix metal. The corrosion resistance of alloys in di?erent conditions decreased in the following order: the weld beam >6061 Al > AMC.
关键词： aluminum matrix composite,laser welding,TiB2 particles,microstructure,6061 aluminum alloy,dissimilar metal joints,corrosion properties
更新于2025-11-21 11:18:25
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Optimization of laser welding process parameters in dissimilar joint of stainless steel AISI316/AISI1018 low carbon steel to attain the maximum level of mechanical properties through PWHT
摘要： In this investigation, laser welding process parameters have been optimized for austenitic stainless steel (AISI316) and low carbon steel (AISI1018) materials by using Taguchi based grey relational analysis. Butt joint trials were carried out using 3.5 kW di?usion-cooled slab CO2 laser by varying laser power, welding speed, and focal distance. The optimum parameters have been derived by considering the responses such as tensile strength and microhardness. The optimal parameters are laser power 2600 W, welding speed 1.5 m/min and focal distance 20 mm. The responses of the optimized parameters obtained using the grey relational analysis has been veri?ed experimentally. Formerly, the e?ect of post weld heat treatment (860 °C and 960 °C) on the mechanical properties, microstructure and chemical composition of weld zone of the optimal welded joint was investigated by using tensile test, microhardness, bend test, optical microscope, SEM and EDS. The results show that the optimal welded joint had good mechanical properties after post weld heat treatment so that the best tensile strength 475.112 MPa was obtained at 960 °C. Due to the elimination of chromium carbide and reduce grain size, the heat treated samples show high corrosion resistance at 960 °C in comparison to 860 °C.
关键词： Metallurgical properties,Laser welding,Mechanical properties,Dissimilar metals,PWHT,GRA
更新于2025-09-23 15:21:21
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20a??kW laser welding applied on the international thermonuclear experimental reactor correction coil case welding
摘要： International thermonuclear experimental reactor correction coil cases are made of heavy, thick, high strength, and high toughness austenitic stainless steel 316LN. The BTCC (bottom and top correction coils) case has the dimension of 2.5 × 7 m2 and cross section of 239.8 × 146.7 mm2, side correction coil case has the dimension of 7.2 × 7.6 m2 and cross section of 147.8 × 168 mm2, and they will be closure welded after winding pack insertion. The 20 mm welding depth, dozens of meter of welding length, strict welding requirements, large size, and complex configuration bring a big challenge to this closure welding work. 20 kW high power laser welding is selected as the main welding method because of the advantage of potential welding deformation control and its penetrating ability and cracking resistance. The welding parameter is developed that can cover the assembly gap from 0 to 0.5 mm with a good welding quality. A special test coupon is designed for the welding procedure qualification, and related tests are carried out to qualify the joint properties of bend, tensile, and impact. Finally, a full-scale BTCC case is welded. After welding, ultrasonic testing confirms that almost all welds satisfy the weld seam quality requirement. The recorded temperatures less than 250° indicate that the temperature induced by welding will not harm the internal winding pack. The dimensional deviation of the inner face is less than 4 mm and also satisfies the tolerance requirement of ±2 mm for the BTCC case.
关键词： austenitic stainless steel,ITER,welding deformation,cracking,20kW laser welding
更新于2025-09-23 15:21:01
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Laser-arc hybrid welding of 12- and 15-mm thick structural steel
摘要： High-power lasers are very effective in welding of plates thicker than 10 mm due to the keyhole mode. High-power intensity generates a vapor-filled cavity which provides substantial penetration depth. Due to the narrow and deep weld geometry, there is susceptibility to high hardness and weld defects. Imperfections occur due to keyhole instability. A 16-kW disk laser was used for single-pass welding of 12- to 15-mm thick plates in a butt joint configuration. Root humping was the main imperfection and persisted within a wide range of process parameters. Added arc source to the laser beam process may cause increased root humping and sagging due to accelerated melt flow. Humping was mitigated by balancing certain arc and other process parameters. It was also found that lower welding speeds (< 1.2 m/min) combined with lower laser beam power (< 13 kW) can be more positive for suppression of humping. Machined edges provided more consistent root quality and integrity compared with plasma cut welded specimens. Higher heat input (> 0.80 kJ/mm) welds provided hardness level below 325 HV. The welded joints had good Charpy toughness at ? 50 °C (> 50 J) and high tensile strength.
关键词： Mechanical properties,Toughness,Thick steel,Hybrid welding,High strength steel,Laser welding
更新于2025-09-23 15:21:01
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Study on the Droplet Transition Models in Laser Welding with Filler Wire
摘要： This study is intended to examine the droplet transition in the welding process. Tests were performed using a high-speed camera to assess the effect of the vertical distance between the laser–wire intersection and workpiece (H) on droplet transition. Meanwhile, forces on the droplet were analyzed to evaluate the transition model during laser welding with filler wire. The results showed transition frequency, that droplet size and forces of the model all changed with H level changing. Droplet transition and the welding process showed stability at an H level of 1 mm. Based on the liquid bridge transition model, the droplet was transferred to the molten pool in the state of balance, while the droplet entered into the molten pool under non-equilibrium state during globular transition.
关键词： Droplet transition,Laser welding with filler wire,Vertical distance between the laser–wire intersection and workpiece,Force analysis of droplet
更新于2025-09-23 15:21:01
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Direct observation of pore formation mechanisms during LPBF additive manufacturing process and high energy density laser welding
摘要： Laser powder bed fusion (LPBF) is a 3D printing technology that can print parts with complex geometries that are unachievable by conventional manufacturing technologies. However, pores formed during the printing process impair the mechanical performance of the printed parts, severely hindering their widespread application. Here, we report six pore formation mechanisms that were observed during the LPBF process. Our results reconfirm three pore formation mechanisms - keyhole induced pores, pore formation from feedstock powder and pore formation along the melting boundary during laser melting from vaporization of a volatile substance or an expansion of a tiny trapped gas. We also observe three new pore formation mechanisms: (1) pore trapped by surface fluctuation, (2) pore formation due to depression zone fluctuation when the depression zone is shallow and (3) pore formation from a crack. The results presented here provide direct evidence and insight into pore formation mechanisms during the LPBF process, which may guide the development of pore elimination/mitigation approaches. Since certain laser processing conditions studied here are similar to the situations in high energy density laser welding, the results presented here also have implications for laser welding.
关键词： Pore formation,Laser powder bed fusion,X-ray imaging,Laser welding,Additive manufacturing
更新于2025-09-23 15:21:01
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Development of low vacuum laser welding technique using an aerodynamic window; ??o????a?????????¨???????????§??°?￠?????????????????o???￥???è??é????o;
摘要： In order to realize deep laser welding, conceptual application of a supersonic jet as an aerodynamic window was investigated. Detailed characteristics of the supersonic jet as the aerodynamic window were studied experimentally. Flow field of the supersonic jet was examined based on the schlieren flow visualization technique. As compared to a free-vortex flow design applied to the aerodynamic window nozzle, in the case of supersonic jet, oblique shock waves were captured both at the nozzle exit edge and the shear layer on the aerodynamic window. The velocity field under the condition that the shock-expansion wave was formed in the aerodynamic window was measured by the PIV (Particle Image Velocimetry) system (Koncerto II, Seika Digital Image Corp.). Both the vorticity magnitude and angular momentum were analyzed. Level of the vorticity magnitude in the core region of the supersonic jet was smaller by one-order than that in the shear layer in the region corresponding to the passage of laser-light (θ = 30 to 40° and r = 23.8 to 27.1 mm). The radial and circumferential velocity product in this region was similar to that observed under the free-vortex condition. In addition to the measurement mentioned above, pressure behavior was investigated using a multi-pressure measuring system (Scanivalve Corp. ZOC33). When the reservoir pressure was set at 800 kPa and diffuser width as 30.0mm, cavity pressure was reduced to 10.0 kPa. Under this reduced pressure environment, penetration depth increased by 2.6 times compared to penetration depth under atmospheric pressure environment. The effectiveness of the supersonic free-vortex aerodynamic window system tested in the high power laser welding manufacturing has been proven by the present study.
关键词： PIV,Aerodynamic window,High power laser welding,Flow visualization,Supersonic flow,Schlieren
更新于2025-09-23 15:21:01
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Study on the intelligent model database modeling the laser welding for aerospace aluminum alloy
摘要： With the purpose of improving the modeling e?ciency, the model database is established targeting that in-telligent modeling of laser welding for aerospace aluminum alloy. The model database consists of material database, heat source model database and weld joint structure database. The aerospace aluminum alloys are classi?ed reasonably in order to establish the material model database which can manage the thermo-physical properties of aluminum alloys. The heat source models of laser welding are summarized to establish model database on the basis of the di?erent energy distribution characteristics. The joint structure database includes butt joint, T-joint and lap joint. Modeling of arbitrary structures can be implemented quickly and e?ciently when modelers invoke and assemble this model database. The ?nite element model is e?ciently established and accurately solved by taking the 5A90 and 2219 aluminum alloy laser welding as an example. Finally, it is found that the model database established in this paper can greatly improve the modeling e?ciency of laser welding numerical simulation.
关键词： Laser welding,Model database,Aluminum alloy,Structural model,Heat source model,Material model
更新于2025-09-23 15:21:01
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Measurement of Weld Zone Properties of Laser-Welded Tailor-Welded Blanks and Its Application to Deep Drawing
摘要： Weld zones in tailor welded blanks have different mechanical properties than the base metals and thus have significant effects on formability. In this work, flow stresses of weld zones in laser-welded dissimilar dual-phase steels were measured. Strains at the weld zones of notched specimens were measured using the digital image correlation method and the flow stress data were corrected considering the anisotropy. For validation, finite element simulations were performed for the cup drawing process by considering the measured weld zone properties, and the weld line movements were compared with the measurements.
关键词： Laser welding,Formability,Digital image correlation,Dual-phase steel,Flow stress
更新于2025-09-23 15:21:01
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Weldability and mechanical behavior of laser-welded TRIP 750 steel sheets
摘要： Transformation-induced plasticity steels have been developed and widely applied in the automotive and aerospace industries. They exhibit ductility and mechanical strength associated with a high formability due to their complex microstructure of bainite-associated pro-eutectoid ferrite and significant retained austenite fractions. The weldability of these steels is limited by the high content of alloying elements in the composition, causing the thermal cycle to modify the carefully designed microstructure, which in turn generates unsatisfactory weld mechanical properties. Laser welding has a relatively low thermal input, and, therefore, a narrow heat-affected zone is obtained. As known, the literature had not been definitively reported the microstructural features of the fusion and the heat-affected zones after laser welding of TRIP steels in conjunction with their mechanical behavior. The aim of the present work is to characterize the microstructure and mechanical behavior of laser-welded TRIP steel after uniaxial tensile and Erichsen formability tests. The coupons of TRIP 750 steel sheets were subjected to different laser welding conditions in order to analyze their impact on the microstructure, hardness, and mechanical strength of the material. After some preliminary tests, the laser power was fixed at 900 W and the weld speed fixed at 50 mm/s as the best choice of operating parameters. Under these conditions, the fusion zone was almost completely martensitic, while the heat-affected zone had a mixture of ferrite and martensite. The martensite transformation is corroborated by finite elements analyses as the cooling rate was 4200 °C/s for material at martensite start temperature. The average hardness of the fusion zone was 530 HV and the heat-affected zone was 550 HV, compared with 270 HVof the base material. In terms of mechanical behavior, the tensile strength of the welded coupons was found to reach 740 MPa and the ductility reached 22% in uniform deformation. The Erichsen index for the welded sheets attained 15 mm for a load of 48.5 kN, similar with the non-welded base material. Both in the case of the uniaxial tensile testing and in the Erichsen testing, the fracture occurred in the base material away from the weld, showing a good toughness of the welded component.
关键词： Transformation-induced plasticity steels,Microstructure,Hardness,Tensile testing,Erichsen testing,Laser welding
更新于2025-09-23 15:21:01