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Chinese Journal of Lasers, Volume. 49, Issue 2, 0202020(2022)

Effects of Heat Source Angle on Weld Formation and Porosity Defects of Laser-MIG Hybrid Welding of 6A01 Aluminum Alloy

Xiaohui Han1, Zhiyi Zhang1, Guolong Ma1, Laijun Wu2,3, Xiaoguo Song2,3, Houqin Wang2, and Caiwang Tan2,3、*
Author Affiliations
  • 1CRRC Qingdao Sifang Co., LTD., Qingdao, Shandong 266111, China
  • 2State Key Laboratory of Advanced Welding and Joining, Harbin Institute of Technology, Harbin, Heilongjiang 150001, China
  • 3Shandong Provincial Key Laboratory of Special Welding Technology, Harbin Institute of Technology at Weihai, Weihai, Shandong 264209, China
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    References (15)
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    Figures & Tables(14)
    Aluminum extrusions. (a) Appearances; (b) welds

    Fig. 1. Aluminum extrusions. (a) Appearances; (b) welds

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    Laser-MIG hybrid welding processing

    Fig. 2. Laser-MIG hybrid welding processing

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    Angle settings of the heat source in six tests. (a) Test 1; (b) test 2; (c) test 3; (d) test 4; (e) test 5; (f) test 6

    Fig. 3. Angle settings of the heat source in six tests. (a) Test 1; (b) test 2; (c) test 3; (d) test 4; (e) test 5; (f) test 6

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    Weld appearances and cross-sections under different angle settings. (a) Test 1, α＝82.5°，β＝120°；(b) test 2, α＝82.5°，β＝140°；(c) test 3, α＝70°，β＝140°；(d) test 4, α＝97.5°，β＝120°；(e) test 5, α＝97.5°，β＝140°； (f) test 6, α＝110°，β＝140°

    Fig. 4. Weld appearances and cross-sections under different angle settings. (a) Test 1, α＝82.5°，β＝120°；(b) test 2, α＝82.5°，β＝140°；(c) test 3, α＝70°，β＝140°；(d) test 4, α＝97.5°，β＝120°；(e) test 5, α＝97.5°，β＝140°；　(f) test 6, α＝110°，β＝140°

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    Weld depth and width under different angle settings

    Fig. 5. Weld depth and width under different angle settings

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    Steps for calculating weld porosity. (a) Cross-sections; (b) gray level image; (c) threshold segmentation

    Fig. 6. Steps for calculating weld porosity. (a) Cross-sections; (b) gray level image; (c) threshold segmentation

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    Cross-sections and binary images of welds under different angle settings. (a) Test 1, α＝82.5°，β＝120°；(b) test 2, α＝82.5°，β＝140°；(c) test 3, α＝70°，β＝140°；(d) test 4, α＝97.5°，β＝120°；(e) test 5, α＝97.5°，β＝ 140°；(f) test 6, α＝110°，β＝140°

    Fig. 7. Cross-sections and binary images of welds under different angle settings. (a) Test 1, α＝82.5°，β＝120°；(b) test 2, α＝82.5°，β＝140°；(c) test 3, α＝70°，β＝140°；(d) test 4, α＝97.5°，β＝120°；(e) test 5, α＝97.5°，β＝　　140°；(f) test 6, α＝110°，β＝140°

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    Porosity of welds under different angle settings

    Fig. 8. Porosity of welds under different angle settings

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    Electricity signals, metal transfer and weld pool of welds under different angle settings. (a) Test 1, α＝82.5°，β＝120°；(b) test 2, α＝82.5°，β＝140°；(c) test 2, α＝70°，β＝140°；(d) test 4, α＝97.5°，β＝120°；(e) test 5, α＝ 97.5°，β＝140°；(f) test 6, α＝110°，β＝140°

    Fig. 9. Electricity signals, metal transfer and weld pool of welds under different angle settings. (a) Test 1, α＝82.5°，β＝120°；(b) test 2, α＝82.5°，β＝140°；(c) test 2, α＝70°，β＝140°；(d) test 4, α＝97.5°，β＝120°；(e) test 5, α＝　　97.5°，β＝140°；(f) test 6, α＝110°，β＝140°

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    Fluent finite element simulation analysis modeling process. (a) Welding model; (b) meshing; (c) droplet settings

    Fig. 10. Fluent finite element simulation analysis modeling process. (a) Welding model; (b) meshing; (c) droplet settings

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    Simulation results of the cross-sections and weld pool of welds under different angle settings. (a) Test 1, α＝82.5°，β＝120°；(b) test 2, α＝82.5°，β＝140°；(c) test 3, α＝70°，β＝140°；(d) test 4, α＝97.5°，β＝120°； (e) test 5, α＝97.5°，β＝140°；(f) test 6, α＝110°，β＝140°

    Fig. 11. Simulation results of the cross-sections and weld pool of welds under different angle settings. (a) Test 1, α＝82.5°，β＝120°；(b) test 2, α＝82.5°，β＝140°；(c) test 3, α＝70°，β＝140°；(d) test 4, α＝97.5°，β＝120°；　(e) test 5, α＝97.5°，β＝140°；(f) test 6, α＝110°，β＝140°

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    Comparison of simulation results and measured results of the weld depth and width. (a) Weld width; (b) weld depth

    Fig. 12. Comparison of simulation results and measured results of the weld depth and width. (a) Weld width; (b) weld depth

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    • Table 1. Chemical composition of used materials (mass fraction, %)

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      Table 1. Chemical composition of used materials (mass fraction, %)

      MaterialsSiMnMgZnFeCrTiAl
      6A010.600.400.680.100.250.200.08Balance
      ER53560.250.205.500.100.400.200.20Balance

    • Table 2. Processing parameters of laser-MIG hybrid welding

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      Table 2. Processing parameters of laser-MIG hybrid welding

      Welding parametersValue
      Laser power /kW4
      Welding speed /(m·min－1)1.8
      Welding current /A180
      Welding voltage /V23
      Wire feeding speed /(m·min－1)8.1
      Distance between laser and arc /mm2
      Protect gas flow rate /(L·min－1)20
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    Xiaohui Han, Zhiyi Zhang, Guolong Ma, Laijun Wu, Xiaoguo Song, Houqin Wang, Caiwang Tan. Effects of Heat Source Angle on Weld Formation and Porosity Defects of Laser-MIG Hybrid Welding of 6A01 Aluminum Alloy[J]. Chinese Journal of Lasers, 2022, 49(2): 0202020

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    Paper Information

    Category: laser manufacturing

    Received: Jun. 15, 2021

    Accepted: Aug. 10, 2021

    Published Online: Jan. 11, 2022

    The Author Email: Tan Caiwang (tancaiwang@hitwh.edu.cn)

    DOI:10.3788/CJL202249.0202020

    Topics

    laser devices and laser physics
    Lasers and Laser Optics
    Laser physics
    laser manufacturing
    Instrumentation, Measurement and Metrology