Optimization of Laser Welding Parameters in Aluminum Alloy Welding and Development of Quality Monitoring System for Light Weight Vehicle

2012 ◽  
Vol 706-709 ◽  
pp. 2998-3003 ◽  
Author(s):  
Young Whan Park ◽  
Dong Yun Kim
Keyword(s):  
Tensile Strength ◽  
Aluminum Alloy ◽  
Laser Welding ◽  
Monitoring System ◽  
Welding Speed ◽  
Feed Rate ◽  
Laser Power ◽  
Filler Wire ◽  
Weld Quality ◽  
Wire Feed

In this paper laser welding AA5182 of aluminum alloy with AA5356 filler wire were performed with respect to laser power, welding speed, and wire feed rate. The experiments showed that the tensile strength of the weld was higher than that of the base material under sufficient heat input conditions. A genetic algorithm was used to optimize process parameters which were the laser power, welding speed, and wire feed rate. To do that, a fitness function was formulated, taking into account weldability and productivity. A factor for the weldabilty used tensile strength estimation model which was made by neural network, and as the productivity, welding speed, and wire feed rate were used. Weld monitoring system for aluminum laser welding with filler wire was constructed through the optical sensors to measure the plasma light intensity. Relationship between monitoring signal and plasma and keyhole behavior according to welding condition was analyzed and it was found that sensor signal could express the information for weld quality. Weld quality estimation algorithm was formulated fuzzy multi feature pattern recognition algorithm using the monitoring signals. Quality prediction system was also developed to apply this algorithm to production line.

scholarly journals The Study on Mechanical Strength of Titanium-Aluminum Dissimilar Butt Joints by Laser Welding-Brazing Process

Materials ◽  
2019 ◽  
Vol 12 (5) ◽  
pp. 712 ◽  
Author(s):  
Xiongfeng Zhou ◽  
Ji’an Duan ◽  
Fan Zhang ◽  
Shunshun Zhong
Keyword(s):  
Tensile Strength ◽  
Laser Welding ◽  
Welding Speed ◽  
Laser Power ◽  
Butt Joint ◽  
Interface Fracture ◽  
Welding Parameters ◽  
Fracture Roughness ◽  
Joint Properties ◽  
5A06 Aluminum Alloy

Laser welding–brazing of 5A06 aluminum to Ti6Al4V titanium in a butt configuration was carried out to discuss the influences of welding parameters on dissimilar joint properties. The effects of laser offset, welding speed, and laser power on the spreading length of the molten aluminum liquid, interface fracture zone width (IFZW), fracture roughness, intermetallic compounds (IMCs) thickness, and tensile strength were also investigated. The microstructure and fracture of the joint were also studied. The results show that the tensile strength of the joint is not only influenced by the thickness and type of IMCs, but also influenced by the spreading ability of the aluminum liquid, the fracture area broken at the Ti/fusing zone (FZ) interface, and the relative area of the brittle and ductile fracture in FZ. A dissimilar butt joint with an IMC thickness of 2.79 μm was obtained by adjusting the laser offset, welding speed, and laser power to 500 μm, 11 mm/s and 1130 W, respectively. The maximum tensile strength of the joint was up to 183 MPa, which is equivalent to 83% of the tensile strength of the 5A06 aluminum alloy.

Effect of Filler Wire Composition on the Nd:YAG Laser Weldability of 6061 Aluminum Alloy

2005 ◽  
Vol 475-479 ◽  
pp. 2591-2594 ◽  
Author(s):  
Jong Won Yoon ◽  
Young Sup Lee ◽  
Kyoung Don Lee ◽  
Ki Young Park
Keyword(s):  
Tensile Strength ◽  
Aluminum Alloy ◽  
Grain Boundaries ◽  
Nd:Yag Laser ◽  
Solidification Cracking ◽  
Filler Wire ◽  
6061 Aluminum Alloy ◽  
Wire Feed

2 mm thick 6061-T6 aluminum alloy sheets were I square butt welded using 3kW Nd:YAG laser. Filler wires of 1 mm diameter, 5183A(Al-4wt.%Mg), 4043A(Al-5wt.%Si) and 4047A (Al-12wt.%Si) were used. The welds made with 4047A wire showed the lowest solidification cracking among the welds investigated. Abundant amount of Al-12wt.%Si eutectic which was observed at the grain boundaries of the 4047A wire feed welds was closely related with the reduced solidification cracking susceptibility. Yield and tensile strength, and formability of the welds made with 4047A wire were improved compared to the welds made with other filler wires, which is attributed to the reduced cracking susceptibility in the welds.

Effect of laser welding speed on the weld quality of a 5A06 aluminum alloy

2018 ◽  
Vol 60 (11) ◽  
pp. 1085-1092 ◽  
Author(s):  
Xiaoli Ma ◽  
Jian Lin ◽  
Jiang Ju ◽  
Yongping Lei ◽  
Hanguang Fu
Keyword(s):  
Aluminum Alloy ◽  
Laser Welding ◽  
Welding Speed ◽  
Weld Quality ◽  
5A06 Aluminum Alloy

scholarly journals Laser-CMT Hybrid Welding-Brazing of Al/Steel Butt Joint: Weld Formation, Intermetallic Compounds, and Mechanical Properties

Materials ◽  
2019 ◽  
Vol 12 (22) ◽  
pp. 3651 ◽  
Author(s):  
Yuxin Chen ◽  
Zhibin Yang ◽  
Chunyuan Shi ◽  
Zhibin Xin ◽  
Zitong Zeng
Keyword(s):  
Tensile Strength ◽  
Aluminum Alloy ◽  
Intermetallic Compounds ◽  
Welding Speed ◽  
Laser Power ◽  
Hybrid Welding ◽  
Imcs Layer ◽  
Feeding Speed ◽  
Wire Feeding ◽  
Interface Layers

6A01-T5 aluminum alloy and SUS301L-DLT austenitic stainless steel sheets were welded by a laser-cold metal transfer (CMT) hybrid welding-brazing method with ER5183 filler wire. We researched the weld forming, intermetallic compounds, and mechanical character, which are influenced by laser power, wire feeding speed, and welding speed. Well-formed joints with uniformly distributed interface layers were obtained under certain parameters. The spreading and wetting distance on the steel upper surface increased initially and then decreased as the laser power increased, and increased progressively as the wire feeding speed increased or welding speed decreased. There were both Fe2Al5 and Fe4Al13 in the interfacial intermetallic compounds (IMCs) layer. The thickness was controlled to within 2.0–6.9 µm. The thickness of the IMCs layer increased as the heat input increased; however, the increasing rate decreased gradually. The tensile strength of the joints was not only completely dependent on the thickness of the IMCs, but also on the spreading and wetting distance on the steel surface. The highest tensile strength could reach up to 188.7 MPa, which is about 77.1% of that of the base aluminum alloy. The tensile sample fracture occurred at the IMCs layer, and regional metallurgical bonding happened in the interface layer.

scholarly journals Optimization and Prediction of Ultimate Tensile Strength in Metal Active Gas Welding

2015 ◽  
Vol 2015 ◽  
pp. 1-5 ◽  
Author(s):  
Anusit Ampaiboon ◽  
On-Uma Lasunon ◽  
Bopit Bubphachot
Keyword(s):  
Tensile Strength ◽  
Ultimate Tensile Strength ◽  
Regression Model ◽  
Flow Rate ◽  
Welding Speed ◽  
Feed Rate ◽  
Gas Flow ◽  
Welding Parameters ◽  
Gas Flow Rate ◽  
Wire Feed

We investigated the effect of welding parameters on ultimate tensile strength of structural steel, ST37-2, welded by Metal Active Gas welding. A fractional factorial design was used for determining the significance of six parameters: wire feed rate, welding voltage, welding speed, travel angle, tip-to-work distance, and shielded gas flow rate. A regression model to predict ultimate tensile strength was developed. Finally, we verified optimization of the process parameters experimentally. We achieved an optimum tensile strength (558 MPa) and wire feed rate, 19 m/min, had the greatest effect, followed by tip-to-work distance, 7 mm, welding speed, 200 mm/min, welding voltage, 30 V, and travel angle, 60°. Shield gas flow rate, 10 L/min, was slightly better but had little effect in the 10–20 L/min range. Tests showed that our regression model was able to predict the ultimate tensile strength within 4%.

Fiber Laser Welding of Noncombustible Magnesium Alloy

2008 ◽  
Vol 580-582 ◽  
pp. 479-482 ◽  
Author(s):  
Yuji Sakai ◽  
Kazuhiro Nakata ◽  
Takuya Tsumura ◽  
Mitsuji Ueda ◽  
Tomoyuki Ueyama ◽  
...  
Keyword(s):  
Tensile Strength ◽  
Magnesium Alloy ◽  
Laser Welding ◽  
Fiber Laser ◽  
Vickers Hardness ◽  
Laser Power ◽  
Welded Joint ◽  
Welding Process ◽  
Fiber Laser Welding ◽  
Laser Welding Process

Noncombustible magnesium alloy AMC602 (Mg-6mass%Al-2mass%Ca) extruded sheet of 2.0mm thickness was successfully welded using a fiber laser welding process at welding speed of 10m/min at 3kW laser power. Tensile strength of the welded joint was about 82 to 88% of that of the base metal. Vickers hardness, tensile strength and micro structural properties are also discussed.

Multi-Objective Optimisation of Laser Deposition of Metal Matrix Composites for Surface Coating Using Principal Component Analysis

2018 ◽  
Vol 40 ◽  
pp. 9-21 ◽  
Author(s):  
Peter Kayode Farayibi
Keyword(s):  
Feed Rate ◽  
Surface Coating ◽  
Laser Power ◽  
Traverse Speed ◽  
Laser Deposition ◽  
Powder Feed Rate ◽  
Multi Objective ◽  
Powder Feed ◽  
Output Characteristics ◽  
Wire Feed

Laser deposition is an advanced manufacturing technology capable of enhancing service life of engineering components by hard-facing their functional surfaces. There are quite a number of parameters involved in the process and also desirable output characteristics. These output characteristics are often independently optimised and which may lead to poor outcome for other characteristics, hence the need for multi-objective optimisation of all the output characteristics. In this study, a laser deposition of Ti-6Al-4V wire and tungsten carbide powder was made on a Ti-6Al-4V substrate with a view to achieve a metallurgical bonded metal matrix composite on the substrate. Single clads were deposited with a desire to optimise the composite clad characteristics (height, width and reinforcement fraction) for the purpose of surface coating. Processing parameters (laser power, traverse speed, wire feed rate, powder feed rate) were varied, the experiment was planned using Taguchi method and output characteristics were analysed using principal component analysis approach. The results indicated that the parameters required for optimised clad height, width, and reinforcement fraction necessary for surface coating is laser power of 1800 W, traverse speed of 200 mm/min, wire feed rate 700 mm/min and powder feed rate of 30 g/min. The powder feed rate was found to most significantly contribute 43.99%, followed by traverse speed 39.77%, laser power 15.87% with wire feed rate having the least contribution towards the multi-objective optimisation. Confirmation results showed that clad width and reinforcement fraction were significantly improved by the optimised parameters. The multi-objective optimisation procedure is a useful tool necessary to identify the process factors required to enhance output characteristics in laser processing.

Numerical Analysis of Solidification Behavior during Laser Welding Nickel-Based Single-Crystal Superalloy Part: II Crystallography-Dependent Supersaturation of Liquid Aluminum

2021 ◽  
Vol 1018 ◽  
pp. 13-22
Author(s):  
Zhi Guo Gao
Keyword(s):  
Laser Welding ◽  
Single Crystal ◽  
Weld Pool ◽  
Welding Speed ◽  
Heat Input ◽  
Laser Power ◽  
Liquid Aluminum ◽  
Dendrite Growth ◽  
Solidification Cracking ◽  
Solid Liquid Interface

The thermal metallurgical modeling of liquid aluminum supersaturation was further developed through couple of heat transfer model, dendrite selection model, multicomponent dendrite growth model and nonequilibrium solidification model during three-dimensional nickel-based single-crystal superalloy weld pool solidification. The welding configuration plays more important role in supersaturation of liquid aluminum, morphology instability and nonequilibrium partition behavior. The bimodal distribution of liquid aluminum supersaturation along the solid/liquid interface is crystallographically symmetrical about the weld pool centerline in (001) and [100] welding configuration. The distribution of liquid aluminum supersaturation along the solid/liquid interface is crystallographically asymmetrical throughout the weld pool in (001) and [110] welding configuration. Optimum low heat input (low laser power and high welding speed) with (001) and [100] welding configuration is more favored to predominantly promote epitaxial [001] dendrite growth to reduce the metallurgical factors for solidification cracking than that of high heat input (high laser power and slow welding speed) with (001) and [110] welding configuration. The lower the heat input is used, the lower supersaturation of liquid aluminum is imposed, and the smaller size of vulnerable [100] dendrite growth region is incurred to ameliorate solidification cracking susceptibility and vice versa. The overall supersaturation of liquid aluminum in (001) and [100] welding configuration is beneficially smaller than that of (001) and [110] welding configuration regardless of heat input, and is not thermodynamically relieved by gamma prime γˊ phase. (001) and [110] welding configuration is detrimental to weldability and deteriorates the solidification cracking susceptibility because of unfavorable crystallographic orientations and alloying aluminum enrichment. The mechanism of asymmetrical solidification cracking because of crystallography-dependent supersaturation of liquid aluminum is proposed. The eligible solidification cracking location is particularly confined in [100] dendrite growth region. Moreover, the theoretical predictions agree well with the experiment results. The useful modeling is also applicable to other single-crystal superalloys with similar metallurgical properties for laser welding or laser cladding. The thorough numerical analyses facilitate the understanding of weld pool solidification behavior, microstructure development and solidification cracking phenomena in the primary γ phase, and thereby optimize the welding conditions (laser power, welding speed and welding configuration) for successful crack-free laser welding.

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