scholarly journals Effect of Droplet Transition on the Dynamic Behavior of the Keyhole during 6061 Aluminum Alloy Laser-MIG Hybrid Welding

2021 ◽  
Author(s):  
Yue Li ◽  
Yanqiu Zhao ◽  
Xudong Zhou ◽  
Xiaohong Zhan
Keyword(s):  
Aluminum Alloy ◽  
Dynamic Behavior ◽  
Molten Pool ◽  
High Speed ◽  
Welding Process ◽  
Welding Parameters ◽  
Hybrid Welding ◽  
Camera System ◽  
6061 Aluminum Alloy ◽  
Droplet Transition

Abstract The simulation method in laser-MIG hybrid welding, which involves two heat sources and multiple welding parameters, is beneficial to reveal the complex physical phenomena and dynamic behavior of molten pool keyhole during welding process. In this investigation, laser-MIG hybrid welding for 6-mm-thick 6061 aluminum alloy was performed under different heat input by the high-power disc laser, MIG welding system and KUKA Robot. The high-speed camera system was used to observe the droplet transition phenomenon in the welding process. Besides, a thermal-fluid coupling model was established to simulate the temperature field and flow field, which were changed by the droplet transfer during laser-MIG hybrid welding. The experimental and simulated results showed that the droplet transition behavior affected the formation of the keyhole. The keyhole was the smallest when the droplet contacted the molten pool. In addition, the droplet transition brought external momentum and energy to the molten pool, which was conducive to the increase of the flow rate of the molten pool.

Elements loss analysis based on spectral diagnosis in laser-arc hybrid welding of aluminum alloy

2017 ◽  
Vol 31 (16-19) ◽  
pp. 1744036
Author(s):  
Yong Chen ◽  
Hui Chen ◽  
Minhao Zhu ◽  
Tao Yang ◽  
Lin Shen
Keyword(s):  
Aluminum Alloy ◽  
High Speed ◽  
Welding Process ◽  
Spectral Intensity ◽  
Hybrid Welding ◽  
Loss Analysis ◽  
Welding Defects ◽  
High Speed Trains ◽  
Arc Current ◽  
Weld Area

Aluminum alloy has been widely used in automobiles, high-speed trains, aerospace and many other fields. The loss of elements during welding process causes welding defects and affects the microstructure and properties of the joints. This paper discusses the correlation between welding process, spectral intensity and loss of elements in laser-arc hybrid welding of Al alloys. The results show that laser power and arc current have a significant impact on the spectral intensity and loss of elements. Compared with the base metal, the contents of alloying elements in the weld area are lower. The burning losses of alloy elements increase with the welding heat input.

Investigation of porosity in rotating laser-MIG hybrid welding A6N01 aluminum alloy

2019 ◽  
Vol 33 (01n03) ◽  
pp. 1940029
Author(s):  
Yanjie Yin ◽  
Hui Chen ◽  
Xiaoyi Yang ◽  
Shuang He
Keyword(s):  
Aluminum Alloy ◽  
Molten Pool ◽  
High Speed ◽  
Rotation Frequency ◽  
Good Prospect ◽  
Hybrid Welding ◽  
Weld Penetration ◽  
X Ray ◽  
Conventional Laser ◽  
Alloy Weld

In this study, rotating laser was employed to reduce the porosity defect in laser-MIG hybrid welding A6N01 aluminum alloy. The influence of laser rotating frequency and rotating radius on the weld were researched respectively. The images of the molten pool were acquired by the high-speed camera, and X-ray images of the weld were calculated by binarization. The result shows that rotating laser-MIG hybrid welding has a dramatic effect on suppressing the generation of porosity, which indicates the possibility to obtain the A6N01 aluminum alloy weld with few pores. With proper parameters about rotation frequency (50 Hz) and rotation radius (2 mm), the porosity decreased obviously from 8.41% to 5.68%, and there was hardly distinct change in the weld penetration. The keyhole stability of rotating laser-MIG hybrid welding was improved, compared with the conventional laser-MIG hybrid welding. On account of laser beam stirring the metal molten pool, it was beneficial for the pores to escape from the molten pool. The rotating laser-MIG hybrid welding shows a good prospect.

scholarly journals Comparative Study on Welding Characteristics of Laser-CMT and Plasma-CMT Hybrid Welded AA6082-T6 Aluminum Alloy Butt Joints

Materials ◽  
2019 ◽  
Vol 12 (20) ◽  
pp. 3300 ◽  
Author(s):  
Zhibin Xin ◽  
Zhibin Yang ◽  
Han Zhao ◽  
Yuxin Chen
Keyword(s):  
Aluminum Alloy ◽  
Comparative Study ◽  
Welded Joints ◽  
High Speed ◽  
Shear Fracture ◽  
Welding Process ◽  
Hybrid Welding ◽  
Micro Hardness ◽  
Butt Joints ◽  
Promising Alternative

Laser-CMT (Cold Metal Transfer) and plasma-CMT hybrid welding are two promising alternative joining technologies for traditional Metal-Inert-Gas (MIG) welding of the aluminum alloy joints in the high speed trains manufacturing industry. In this work, a comparative study on the weld formation, microstructure, micro-hardness, and mechanical properties of the butt joints in the two welding methods was conducted. The results indicate that the overall quality of the laser-CMT and plasma-CMT welds were good, especially of the laser-CMT hybrid weld, and the laser-CMT hybrid welding process needed a lower heat input. The width of the partially melted zone of the laser-CMT hybrid weld was narrower than that in the plasma-CMT hybrid weld. Micro-hardness test results show that two distinct softening regions were identified in the heat affected zone, and the micro-hardness values of each zone in the laser-CMT hybrid weld were lower than that in the plasma-CMT hybrid weld. The tensile strength of the laser-CMT hybrid welded joints was higher than that of the plasma-CMT hybrid welded joints, which could reach up to 79.4% and 73.7% of the base materials, respectively. All the fractures occurred in the softening region and exhibited a ductile shear fracture with a shear angle of approximately 45°. The fractographs manifested that the laser-CMT and plasma-CMT hybrid welded joints presented ductile fracture and ductile-brittle fracture features, respectively.

scholarly journals Effect of Laser-arc Hybrid Welding Energy Parameters on Welding Stability

2018 ◽  
Vol 175 ◽  
pp. 02019
Author(s):  
ZHANG Fulong ◽  
ZHANG Hong ◽  
LIU Fengde
Keyword(s):  
High Speed ◽  
Welding Process ◽  
Welding Current ◽  
Hybrid Welding ◽  
Depth Of Penetration ◽  
Arc Power ◽  
Transfer Pattern ◽  
Welding Stability ◽  
Filament Spacing ◽  
Droplet Transition

The high-speed camera was used to collect the droplet transfer pattern and arc pattern of the laser-arc hybrid welding process. Using the methods of image processing and mathematical statistics, the effects of different laser and arc power conditions on the welding stability were studied. The results show that the melting width depends on the welding current, the depth of penetration depends on the laser power, the droplet transition pattern, the actual filament spacing and the arc length determine the welding stability of the laser arc hybrid welding.

Laser-Arc Hybrid Welding Process and Joint Performances of 6106-T6 Aluminum Alloy Profiles for High Speed Trains

2019 ◽  
Vol 46 (12) ◽  
pp. 1202004
Author(s):  
韩晓辉 Han Xiaohui ◽  
李帅贞 Li Shuaizhen ◽  
毛镇东 Mao Zhendong ◽  
温鹏 Wen Peng ◽  
栗忠秀 Li Zhongxiu ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
High Speed ◽  
Welding Process ◽  
Hybrid Welding ◽  
High Speed Trains

Effect of Activating Flux and Welding Parameters on Performance of Aluminum Alloy Weldment in GTA Welding Process

2011 ◽  
Vol 117-119 ◽  
pp. 1900-1904
Author(s):  
Hsuan Liang Lin ◽  
Hung Wei Juang ◽  
Jia Ching Yan
Keyword(s):  
Aluminum Alloy ◽  
Taguchi Method ◽  
Welding Process ◽  
Gta Welding ◽  
Weld Bead ◽  
Welding Parameter ◽  
Welding Parameters ◽  
Alloy Plate ◽  
6061 Aluminum Alloy ◽  
Activating Flux

The purpose of this work was to investigate the effect of activating fluxes and welding parameter to the penetration and depth-to-width ratio (DWR) of 6061 aluminum alloy welds. Bead-on-plate argon gas tungsten arc (GTA) welding process was made on 6061 aluminum alloy of plate without filling metals. The activating fluxes used in the experiment were CaO, ZnO, SiO2, TiO2, Al2O3, Cr2O3, CaF2 and Na2CO3. Based on the higher penetration of weld bead and welding arc voltage, four fluxes were selected to create three new mixtures using 50% of each original fluxes. The mixed fluxes were used to investigate the effect to the welding penetration. Finally, The Taguchi method was employed to achieve optimal DWR of weld bead and investigate the welding parameters that significantly affect welding quality. The experimental procedure of GTA welding with activating flux via the Taguchi method produced full penetration of weld bead on a 6.35 mm thickness of 6061 aluminum alloy plate with single pass weld.

Optimization of Laser-Arc Interspacing Distance during CO2 Laser-GMA Hybrid Welding by Using High-Speed Imaging

2007 ◽  
Vol 26-28 ◽  
pp. 481-484 ◽  
Author(s):  
Cheol Hee Kim ◽  
Hyun Byung Chae ◽  
Jun Ki Kim ◽  
Jeong Han Kim
Keyword(s):  
Laser Welding ◽  
Arc Welding ◽  
High Speed ◽  
Welding Process ◽  
Welding Parameters ◽  
Hybrid Welding ◽  
High Speed Imaging ◽  
Cross Sectional ◽  
Shipbuilding Industry ◽  
Gap Bridging

Laser welding has not easily been adopted in shipbuilding industry because of its poor gap bridging ability. Recently, laser-GMA hybrid welding process showed possibility to overcome the tight gap tolerance with improved productivity. The laser-arc hybrid welding process is inherently complex because it has three kinds of process parameters: arc welding, laser welding and hybrid welding parameters. In this study, welding phenomena were investigated to optimize the hybrid process parameter; interspacing distance between laser and arc. The bead surface and cross-sectional shapes were evaluated, and weld pool shape and droplet transfer were monitored by high speed camera to clarify welding phenomena.

Effects of Wire Rotating Frequency on Metal Transfer Process in Rotating Arc Narrow Gap Horizontal GMAW

2011 ◽  
Vol 189-193 ◽  
pp. 3395-3399 ◽  
Author(s):  
Ning Guo ◽  
Yan Fei Han ◽  
Chuan Bao Jia ◽  
Yong Peng Du
Keyword(s):  
Transfer Process ◽  
High Speed ◽  
Stable Process ◽  
Welding Process ◽  
Metal Transfer ◽  
Welding Parameters ◽  
High Speed Photography ◽  
Narrow Gap ◽  
Weld Formation ◽  
Rotating Arc

The metal transfer process with different welding parameters in rotating arc narrow gap horizontal welding is successfully observed by the high-speed photography system. The effects of wire rotating frequency on metal transfer process in rotating arc narrow gap horizontal welding are novelly explored. The metal transfer with different wire rotating frequency presents different modes. The results indicate that the droplet transfer has stable process with the rotating frequency of 5-20 Hz. And the weld formation is quite shapely. But with the high rotating frequency of 50 Hz, the metal transfer process is not acceptable and the weld formation is very pool. Metal transfer process is one of the most important factors of effecting the weld formation in rotating arc horizontal welding process besides the molten pool behavior and welding thermal circles.

scholarly journals Increasing of the Mechanical Properties of Friction Stir Welded Joints of 6061 Aluminum Alloy by Introducing Alumina Particles

2017 ◽  
Vol 17 (2) ◽  
pp. 29-40 ◽  
Author(s):  
M. A. Tashkandi ◽  
J. A. Al-Jarrah ◽  
M. Ibrahim
Keyword(s):  
Aluminum Alloy ◽  
Base Metal ◽  
Welded Joints ◽  
Volume Fraction ◽  
Welding Process ◽  
Welding Zone ◽  
6061 Aluminum Alloy ◽  
Friction Stir ◽  
Alumina Particles ◽  
Welding Line

AbstractThe main aim of this investigation is to produce a welding joint of higher strength than that of base metals. Composite welded joints were produced by friction stir welding process. 6061 aluminum alloy was used as a base metal and alumina particles added to welding zone to form metal matrix composites. The volume fraction of alumina particles incorporated in this study were 2, 4, 6, 8 and 10 vol% were added on both sides of welding line. Also, the alumina particles were pre-mixed with magnesium particles prior being added to the welding zone. Magnesium particles were used to enhance the bonding between the alumina particles and the matrix of 6061 aluminum alloy. Friction stir welded joints containing alumina particles were successfully obtained and it was observed that the strength of these joints was better than that of base metal. Experimental results showed that incorporating volume fraction of alumina particles up to 6 vol% into the welding zone led to higher strength of the composite welded joints as compared to plain welded joints.

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