Hostname: page-component-586b7cd67f-vdxz6 Total loading time: 0 Render date: 2024-11-30T23:36:23.709Z Has data issue: false hasContentIssue false
  • English
  • Français

Reduced hot cracking susceptibility by controlling the fusion ratio in laser welding of dissimilar Al alloys joints

Published online by Cambridge University Press:  20 March 2015

Yulong Zhang ,
Fenggui Lu ,
Hui-Ping Wang ,
Xiaojie Wang ,
Haichao Cui  and
Xinhua Tang
Yulong Zhang
Affiliation:
Shanghai Key Laboratory of Materials Laser Processing and Modification, Shanghai Jiao Tong University, Shanghai 200240, People's Republic of China
Fenggui Lu*
Affiliation:
Shanghai Key Laboratory of Materials Laser Processing and Modification, Shanghai Jiao Tong University, Shanghai 200240, People's Republic of China; and Shanghai Key Laboratory of Modern Metallurgy and Materials Processing, Shanghai University, Shanghai 200072, People's Republic of China
Hui-Ping Wang
Affiliation:
Manufacturing Systems Research Lab, General Motors Global Research & Development, Warren, Michigan 48090, USA
Xiaojie Wang
Affiliation:
Shanghai Key Laboratory of Materials Laser Processing and Modification, Shanghai Jiao Tong University, Shanghai 200240, People's Republic of China
Haichao Cui
Affiliation:
Shanghai Key Laboratory of Materials Laser Processing and Modification, Shanghai Jiao Tong University, Shanghai 200240, People's Republic of China
Xinhua Tang
Affiliation:
Shanghai Key Laboratory of Materials Laser Processing and Modification, Shanghai Jiao Tong University, Shanghai 200240, People's Republic of China
*
a)Address all correspondence to this author. e-mail: [email protected]
Get access

Abstract

With the increasing usage of Al alloys in vehicle manufacture, it is necessary to join dissimilar Al alloys with lap joint. However, hot cracking is a challenging issue due to the chemical composition and thermal tension, which greatly determines the reliability of automobile operation. Among different Al alloys, the series 5000 (Al–Mg) and 6000 (Al–Mg–Si) are widely used. To better understand the hot cracking behavior, various stack ups of AA5754 and AA6013 were laser welded to investigate the effects of process parameters on hot cracking formation. The chemical composition, microstructure, fusion ratio, and fracture morphology of the weld joint were also examined. The results showed that the order of material stacking affected weld's susceptibility to hot cracking significantly, and the critical process parameters were obtained for tested conditions which could effectively reduce hot cracking. The findings from this work provide guidance for hot cracking prevention in laser welding of dissimilar Al alloys.

Keywords

laser weldinghot crackingdissimilar Al alloysdifferent stack ups
Type
Articles
Information
Journal of Materials Research , Volume 30 , Issue 7 , 14 April 2015 , pp. 993 - 1001
Copyright
Copyright © Materials Research Society 2015 

Access options

Get access to the full version of this content by using one of the access options below. (Log in options will check for institutional or personal access. Content may require purchase if you do not have access.)

References

REFERENCES

Schoenitz, M. and Dreizin, E.L.: Structure and properties of Al–Mg mechanical alloys. J. Mater. Res. 18, 1827 (2003).CrossRefGoogle Scholar
Liu, X., Lan, S., and Ni, J.: Analysis of process parameters effects on friction stir welding of dissimilar aluminum alloy to advanced high strength steel. Mater. Des. 59, 50 (2014).CrossRefGoogle Scholar
Heinz, A., Haszler, A., Keidel, C., Moldenhauer, S., Benedictus, R., and Miller, W.: Recent development in aluminium alloys for aerospace applications. Mater. Sci. Eng., A 280, 102 (2000).CrossRefGoogle Scholar
Živković, D. and Anzulović, B.: The fatigue of 5083 aluminium alloy welds with the shot-peened crater hot-cracks. Mater. Des. 26, 247 (2005).CrossRefGoogle Scholar
Miller, W., Zhuang, L., Bottema, J., Wittebrood, A.J., De Smet, P., Haszler, A., and Vieregge, A.: Recent development in aluminium alloys for the automotive industry. Mater. Sci. Eng., A 280, 37 (2000).CrossRefGoogle Scholar
Brown, K.R., Venie, M.S., and Woods, R.A.: The increasing use of aluminum in automotive applications. JOM 47, 20 (1995).CrossRefGoogle Scholar
Sakayama, T., Naito, Y., Miyazakki, Y., Nose, T., Murayma, G., Saita, K., and Oikawa, H.: Dissimilar metal joining technologies for steel sheet and aluminum alloy sheet in auto body. Nippon Steel Technical Report 103, 91 (2013).Google Scholar
Kumar, A. and Sundarrajan, S.: Optimization of pulsed TIG welding process parameters on mechanical properties of AA 5456 aluminum alloy weldments. Mater. Des. 30, 1288 (2009).CrossRefGoogle Scholar
Zhang, Y. and Zhang, S.: Welding aluminum alloy 6061 with the opposing dual-torch GTAW process. Weld. J. 78, 222-s (1999).Google Scholar
Senthil Kumar, T., Balasubramanian, V., and Sanavullah, M.: Influences of pulsed current tungsten inert gas welding parameters on the tensile properties of AA 6061 aluminium alloy. Mater. Des. 28, 2080 (2007).CrossRefGoogle Scholar
Zhang, Y., Pan, C., and Male, A.: Improved microstructure and properties of 6061 aluminum alloy weldments using a double-sided arc welding process. Metall. Mater. Trans. A 31, 2537 (2000).CrossRefGoogle Scholar
Thomas, W. and Nicholas, E.: Friction stir welding for the transportation industries. Mater. Des. 18, 269 (1997).CrossRefGoogle Scholar
Fahimpour, V., Sadrnezhaad, S., and Karimzadeh, F.: Corrosion behavior of aluminum 6061 alloy joined by friction stir welding and gas tungsten arc welding methods. Mater. Des. 39, 329 (2012).CrossRefGoogle Scholar
Taban, E., Gould, J.E., and Lippold, J.C.: Dissimilar friction welding of 6061-T6 aluminum and AISI 1018 steel: Properties and microstructural characterization. Mater. Des. 31, 2305 (2010).CrossRefGoogle Scholar
Sánchez-Amaya, J.M., Delgado, T., González-Rovira, L., and Botana, F.J.: Laser welding of aluminium alloys 5083 and 6082 under conduction regime. Appl. Surf. Sci. 255, 9512 (2009).CrossRefGoogle Scholar
Okon, P., Dearden, G., Watkins, K., Sharp, M., and French, P.: Laser welding of aluminium alloy 5083. In ICALEO, 1 (2002).Google Scholar
Quintino, L., Costa, A., Miranda, R., Yapp, D., Kumar, V., and Kong, C.: Welding with high power fiber lasers–a preliminary study. Mater. Des. 28, 1231 (2007).CrossRefGoogle Scholar
Jia, J., Yang, S-L., Ni, W-Y., and Bai, J-Y.: Microstructure and mechanical properties of fiber laser welded joints of ultrahigh-strength steel 22MnB5 and dual-phase steels. J. Mater. Res. 29, 2565 (2014).CrossRefGoogle Scholar
Haboudou, A., Peyre, P., Vannes, A.B., and Peix, G.: Reduction of porosity content generated during Nd:YAG laser welding of A356 and AA5083 aluminium alloys. Mater. Sci. Eng., A 363, 40 (2003).CrossRefGoogle Scholar
Chino, Y., Iwasaki, H., and Mabuchi, M.: Cavity growth rate in superplastic 5083 Al and AZ31 Mg alloys. J. Mater. Res. 19, 3382 (2004).CrossRefGoogle Scholar
Behler, K., Berkmanns, J., Ehrhardt, A., and Frohn, W.: Laser beam welding of low weight materials and structures. Mater. Des. 18, 261 (1997).CrossRefGoogle Scholar
El-Batahgy, A. and Kutsuna, M.: Laser beam welding of AA5052, AA5083, and AA6061 aluminum alloys. Adv. Mater. Sci. Eng. 2009, 1 (2009).CrossRefGoogle Scholar
Akhter, R., Ivanchev, L., and Burger, H.P.: Effect of pre/post T6 heat treatment on the mechanical properties of laser welded SSM cast A356 aluminium alloy. Mater. Sci. Eng., A 447, 192 (2007).CrossRefGoogle Scholar
Kuo, T.Y. and Lin, H.C.: Effects of pulse level of Nd-YAG laser on tensile properties and formability of laser weldments in automotive aluminum alloys. Mater. Sci. Eng., A 416, 281 (2006).CrossRefGoogle Scholar
Nagelberg, A.S.: Observations on the role of Mg and Si in the directed oxidation of Al–Mg–Si alloys. J. Mater. Res. 7, 265 (1992).CrossRefGoogle Scholar
Luijendijk, T.: Welding of dissimilar aluminium alloys. J. Mater. Process. Technol. 103, 29 (2000).CrossRefGoogle Scholar
Katayama, S., Kawahito, Y., and Mizutani, M.: Elucidation of laser welding phenomena and factors affecting weld penetration and welding defects. Phys. Procedia 5, 9 (2010).CrossRefGoogle Scholar
Cicală, E., Duffet, G., Andrzejewski, H., Grevey, D., and Ignat, S.: Hot cracking in Al–Mg–Si alloy laser welding—Operating parameters and their effects. Mater. Sci. Eng., A 395, 1 (2005).CrossRefGoogle Scholar
Kou, S.: Solidification and liquation cracking issues in welding. JOM 55, 37 (2003).CrossRefGoogle Scholar
Cao, G. and Kou, S.: Predicting and reducing liquation-cracking susceptibility based on temperature vs. fraction solid. Weld. J. 85, 9-s (2006).Google Scholar
Andersson, B. and Karlsson, L.: Thermal stresses in large butt-welded plates. J. Therm. Stresses 4, 491 (1981).CrossRefGoogle Scholar
Hernandez, L. and North, T.: The influence of external local heating in preventing cracking during welding of aluminum alloy sheet. Weld. J. 63, 84-s (1984).Google Scholar
Ahmed, H., Wells, M., Maijer, D., Howes, B., and van der Winden, M.: Modelling of microstructure evolution during hot rolling of AA5083 using an internal state variable approach integrated into an FE model. Mater. Sci. Eng., A 390, 278 (2005).CrossRefGoogle Scholar
Cao, G. and Kou, S.: Liquation cracking in full penetration Al-Si welds. Weld. J. 84, 63-s (2005).Google Scholar
Huang, C. and Kou, S.: Liquation cracking in full-penetration Al-Mg-Si welds. Weld. J. 83, 111-s (2004).Google Scholar
Zhang, H. and Wang, S.: A first-principles study on hot crack mechanism in Mg-Al-Ca alloys. J. Mater. Res. 27, 1631 (2012).CrossRefGoogle Scholar
Shi, Y., Zhong, F., Li, X., Gong, S., and Chen, L.: Effect of laser beam welding on tear toughness of a 1420 aluminum alloy thin sheet. Mater. Sci. Eng., A 465, 153 (2007).CrossRefGoogle Scholar