Laser Weldability of Aluminum Alloy and Steel

2005 ◽  
Vol 502 ◽  
pp. 481-486 ◽  
Author(s):  
Seiji Katayama ◽  
Sung Min Joo ◽  
Masami Mizutani ◽  
Han Sur Bang
Keyword(s):  
Aluminum Alloy ◽  
Fusion Zone ◽  
Dissimilar Materials ◽  
High Strength ◽  
Butt Joint ◽  
Joint Interface ◽  
Butt Joints ◽  
Alloy Base ◽  
Lap Welding ◽  
Weld Fusion Zone

With the intention of improving butt or lap joint of dissimilar materials, specially devised weld beads together with lap and butt-joints were produced between A5052 and SPCC, where A5052 butt-joint was melted by heat-conduction of SPCC weld bead in addition to the formation of a limited weld fusion zone at the lap part in A5052 alloy. The thickness of intermetallic compounds at the butt-joint interface was approximately 2 μm and free of cracks. It was also revealed that crack-free lap weld metals were formed between aluminum alloy and steel when the penetration was controlled to be of less than 0.3 mm in depth at small heat input. It was moreover found that the majority of a laser weld fusion zone solidified as alpha(bcc)-iron phase containing small amount of aluminum, and cracks were absent in the case of hard intermetallic (AlxFey type) layer of less than 10μm zone. It was confirmed that a weld with lap and butt joints possessed high strength (leading to the load 3500 N to 4,380 N for 40 mm width specimen). In addition, SPCC and A1100 or A5052 were subjected to lap welding with a cw YAG laser, where one to three passes were performed to produce wider bonded areas. Dissimilar steel and aluminum joints with good mechanical properties were obtained, since the fracture occurred in the aluminum alloy base metal in the tensile test. It is concluded that welded joints of high strength can be produced between aluminum alloy and steel with proper devices.

Process Window for Friction Stir Lap Welding of Aluminum Alloy 6061

2014 ◽  
Vol 783-786 ◽  
pp. 2839-2844
Author(s):  
Simon Larose ◽  
Maxime Guérin ◽  
Priti Wanjara
Keyword(s):  
Aluminum Alloy ◽  
Mechanical Performance ◽  
High Strength ◽  
Butt Joint ◽  
Process Window ◽  
Tool Geometry ◽  
Transportation Industry ◽  
Friction Stir ◽  
Planar Surfaces ◽  
Lap Welding

Precipitation-hardenable 6xxx series aluminum alloys are incorporated in many structural components with due consideration of their good combination of properties including a relatively high strength, outstanding extrudability and excellent corrosion resistance. Accordingly, AA6061 has been identified as a very good candidate material for structural lightweighting of transportation vehicles. However, the weldability of aluminum alloy (AA) 6061 by means of conventional technologies such as GMAW and GTAW methods is limited by sensitivity to solidification cracking. In this respect, friction stir welding (FSW) presents a tremendous potential for assembly of aluminum structures for the transportation industry due to the low heat involved that can mitigate crack formation and, thus, translate into improved mechanical performance of the assembly. In this work, FSW of 3.18 mm thick AA6061-T6 sheets in the lap joint configuration was investigated. This configuration is considered to be more challenging for assembly by FSW than the butt joint type due to the orientation of the interface with respect to the welding tools and the necessity to break the oxide layer on two aluminium alloy planar surfaces. Weld trials were performed to examine the influence of the FSW tool geometry and process parameters on the welding defects, microstructure, hardness and bend performance. Unacceptable material expulsion and/or significant thinning in one of the two overlapped sheets were produced under most conditions. A set of FSW tool geometries leading to a viable process operational window under which the risk of defects could be mitigated and/or eliminated was identified in this study.

Microstructural Evolution and Tensile Strength of Laser-Welded Butt Joints of Ultra-High Strength Steels: Low and High Alloy Steels

2021 ◽  
Vol 883 ◽  
pp. 250-257
Author(s):  
Mikko Hietala ◽  
Atef Hamada ◽  
Markku Keskitalo ◽  
Matias Jaskari ◽  
Jani Kumpula ◽  
...  
Keyword(s):  
Tensile Strength ◽  
Fusion Zone ◽  
Microstructural Evolution ◽  
Laser Energy ◽  
High Strength Steels ◽  
High Strength ◽  
Tensile Tests ◽  
Butt Joints ◽  
Dissimilar Joints ◽  
Ultra High Strength Steels

The present study is focused on joining two ultra-high strength steels plates of 3 mm thickness using laser-welding. Abrasion resistant steel with martensitic structure, tensile strength (Rm) ≥ 2 GPa, and cold-deformed austenitic stainless steel, Rm 1.3 GPa, were used for the dissimilar butt joints. Two different laser energy inputs, 160 and 320 J/mm, were presented during welding. The weld morphology and microstructural evolution of the fusion zone were recorded using optical microscopy and electron back scattering diffraction (EBSD), respectively. The mechanical properties of the dissimilar joints were evaluated by hardness measurements and tensile tests. It was found that fusion zone has undergone a change in morphology and microstructure during welding depending upon the energy input. Analysis of the microstructural evolution in the fusion zone by EBSD examination showed that the presence of a mixture of small austenite grains in a matrix of martensite. The changes in hardness profiles and tensile strength under the experimental parameters were further reported.

Understanding of Laser and Hybrid Welding Phenomena

2008 ◽  
Vol 580-582 ◽  
pp. 535-538 ◽  
Author(s):  
Seiji Katayama ◽  
Yousuke Kawahito ◽  
Masami Mizutani
Keyword(s):  
Stainless Steel ◽  
Aluminum Alloy ◽  
Fusion Zone ◽  
Molten Pool ◽  
Bubble Formation ◽  
Hybrid Welding ◽  
Laser Weld ◽  
Pool Surface ◽  
Weld Fusion Zone ◽  
Keyhole Behavior

This paper describes laser and hybrid welding phenomena for the production of a sound and deep weld. The penetration of laser weld beads depended upon the power and power density at low and high welding speeds, respectively. It was reveled that the weld fusion zone geometry was formed by keyhole behavior and melt flows. It was also understood that the production of sound welds without porosity was attributed to no bubble formation in TIG-YAG hybrid welding of stainless steel and the disappearance of bubbles from the molten pool surface in YAG-MIG hybrid welding of aluminum alloy.

Tensile Stress Analyses through Digital Image Correlation of Single Lap Joints of High Strength Steel and Aluminum Alloy Using Adhesive Bonding

2016 ◽  
Vol 879 ◽  
pp. 363-368 ◽  
Author(s):  
P.A.M.G.P. Bamberg ◽  
Uwe Reisgen ◽  
B. Marx ◽  
J.D.V. Barbosa ◽  
R.S. Coelho
Keyword(s):  
Aluminum Alloy ◽  
Stress State ◽  
Digital Image Correlation ◽  
Digital Image ◽  
High Strength Steel ◽  
Dissimilar Materials ◽  
High Strength ◽  
Lap Joints ◽  
Image Correlation ◽  
Single Lap Joints

Structural adhesives methods for joining multi material sheets have been focus of studies and researches for the last years. The most common and widely known type of test is the tensile test of single lap joints (SLJ). However, there are opportunities for analyzing the mechanical performance of such method in SLJ with materials of different properties, such as ductile structural aluminum alloys and high strength steels. It’s also known that the stress state of SLJ, when stressed longitudinally, generates secondary forces. One of them is known as cleavage force which initially leads to the failure of bonded joints. The aim of this work is to analyze the stress state of similar and dissimilar materials SLJ submitted to tensile stresses and also the influence of some variables, such as overlap length, adhesive film thickness and adherend yield limit, over the stress strength of the samples. As adherend materials it was selected the structural aluminum alloy AA 5083 H111 and the high strength steel DP600. At the end of this work it is expected to understand the proper stress state of the SLJ when using similar and dissimilar materials, identifying stress concentrators that bring the structure to fail, using the Digital Image Correlation (DIC) method. It was discovered that the yield strength associated with the overlap length highly influences the SLJ strength, by leading it to a close to pure adhesive shear stress state.

scholarly journals A Review: Laser Welding of Dissimilar Materials (Al/Fe, Al/Ti, Al/Cu)—Methods and Techniques, Microstructure and Properties

Materials ◽  
2021 ◽  
Vol 15 (1) ◽  
pp. 122
Author(s):  
Sergey Kuryntsev
Keyword(s):  
Mechanical Properties ◽  
Laser Beam ◽  
Laser Welding ◽  
Structural Engineering ◽  
Welded Joint ◽  
Dissimilar Materials ◽  
High Strength ◽  
Specific Weight ◽  
Lap Welding ◽  
The Impact

Modern structural engineering is impossible without the use of materials and structures with high strength and low specific weight. This work carries out a quantitative and qualitative analysis of articles for 2016–2021 on the topic of welding of dissimilar alloys. It is found that laser welding is most widely used for such metal pairs as Al/Fe, Al/Ti, and Al/Cu. The paper analyzes the influence of the basic techniques, methods, and means of laser welding of Al/Fe, Al/Ti, and Al/Cu on the mechanical properties and thickness of the intermetallic compound (IMC). When welding the lap joint or spike T-joint configuration of Al/Fe, it is preferable to melt the steel, which will be heated or melted, by the laser beam, and through thermal conduction, it will heat the aluminum. When welding the butt-welded joint of Al/Fe, the most preferable is to melt the aluminum by the laser beam (150–160 MPa). When welding the butt-welded joint of Al/Ti, it is possible to obtain the minimum IMC and maximum mechanical properties by offsetting the laser beam to aluminum. Whereas when the laser beam is offset to a titanium alloy, the mechanical properties are 40–50% lower than when the laser beam is offset to an aluminum alloy. When lap welding the Al/Cu joint, under the impact of the laser beam on the aluminum, using defocusing or wobbling (oscillation) of a laser beam, it is possible to increase the contact area of electrical conductivity with the tensile shear strength of 95–128 MPa.

scholarly journals The Effect of Plume Generated on the Microstructural Behavior of the Weld Mixed Zone in High-Speed Laser Dissimilar Welding

Metals ◽  
2021 ◽  
Vol 11 (10) ◽  
pp. 1556
Author(s):  
Su-Jin Lee ◽  
Seiji Katayama ◽  
Jong-Do Kim ◽  
Jeong Suh
Keyword(s):  
Laser Welding ◽  
Fusion Zone ◽  
High Speed ◽  
Welding Process ◽  
High Strength ◽  
Strength Properties ◽  
Material Behavior ◽  
Dissimilar Welding ◽  
Weld Fusion Zone ◽  
Dissimilar Laser Welding

Dissimilar laser welding has been researched to combine the excellent anticorrosion and high strength properties of Ti and the low weight and cost of Al. However, when welding dissimilar Al and Ti sheets, many kinds of intermetallic compound are easily generated. Therefore, intermetallic compounds and differences in material properties make joining such dissimilar metals very difficult. Previous studies clarified that ultra-high welding speed could suppress the weld defects. To elucidate the mechanism of Al and Ti dissimilar laser welding, material behavior of the weld fusion zone and components of fume generated during the ultra-high speed welding process were observed and analyzed using energy dispersive X-ray spectroscopy (EDX), transmission electron microscopy (TEM), high speed cameras, and a spectrometer. The results show that the atom movement of Al and Ti in the weld plume affects the behavior of elemental components distributed in the weld fusion zone.

scholarly journals Friction Stir Spot Butt Welding of Dissimilar S45C Steel and 6061-T6 Aluminum Alloy

Metals ◽  
2021 ◽  
Vol 11 (8) ◽  
pp. 1252
Author(s):  
Kun Gao ◽  
Shengwei Zhang ◽  
Mounarik Mondal ◽  
Soumyabrata Basak ◽  
Sung-Tae Hong ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Spot Welding ◽  
Energy Dispersive Spectrometry ◽  
Microstructural Analysis ◽  
Tensile Tests ◽  
Joint Interface ◽  
Tool Rotational Speed ◽  
Butt Joints ◽  
Butt Welding ◽  
Friction Stir

Friction stir spot welding (FSSW) of dissimilar S45C steel and 6061-T6 aluminum alloy in a butt configuration is experimentally investigated. Butt spot welding is performed using a convex scrolled shoulder tool at different tool rotational speeds. FSSW butt joints are successfully fabricated by offsetting the tool to the steel side. The microstructures of the joints fabricated at three different tool rotational speeds are characterized using scanning electron microscopy and energy dispersive spectrometry. Microstructural analysis shows the presence of intermetallic compounds (IMCs) along the steel/aluminum interface. The thickness of the IMC layer and the tensile strength of the joint increase with increasing the tool rotational speed. The results of tensile tests and microstructural analysis show that the joint performance is closely related to the IMCs at the joint interface.

Compression Behavior of Adhesive Butt Joints of Aluminum Hexagonal Core Sandwich Panels with Different Edging Configurations

2012 ◽  
Vol 488-489 ◽  
pp. 737-741 ◽  
Author(s):  
S. Rajkumar ◽  
D. Ravindran ◽  
P.K. Arul Raj ◽  
V. Hariprasath
Keyword(s):  
Sandwich Panels ◽  
Weight Ratio ◽  
Fire Retardant ◽  
High Strength ◽  
Butt Joint ◽  
Honeycomb Core ◽  
Butt Joints ◽  
Compression Behavior ◽  
Complex Shapes ◽  
Aluminum Honeycomb

Aluminum honeycomb core sandwich panels are now commercially available and are widely used as light weight materials in aircraft, naval and other applications because of their high strength to weight ratio, high bending stiffness, fire retardant resistance, insulation properties and sound attenuation properties. In all these applications extensive joining is encountered in fabricating the panels to complex shapes. This paper has investigated various edging and configuration details to secure butt joints with adequate soundness through adhesive joining methods. The compression strength of the joints has been assessed experimentally. The configuration of each butt joint is discussed and best combinations of edging and configuration are recommended for successful fabrication of complex assembles with aluminum honey core sandwich panels.

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