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Chinese Journal of Lasers, Volume. 51, Issue 4, 0402102(2024)

Review of Laser-Arc Hybrid Welding Process of Aluminum Alloys for New Energy Vehicles(Invited)

Xiaonan Wang1,2、*, Xiaming Chen1,2, Pengcheng Huan3, Xiang Li4, Qipeng Dong1,2, Shuncun Luo1,2, and Nagaumi Hiromi1,2
Author Affiliations
  • 1School of Iron and Steel, Soochow University, Suzhou 215021, Jiangsu , China
  • 2Jiangsu Engineering Research Center for Green Preparation and Resource Recycling of New Energy Vehicles Metal, Suzhou 215021, Jiangsu , China
  • 3State Key Laboratory of Rolling and Automation, Northeastern University, Shenyang 110819, Liaoning , China
  • 4Ruike Fiber Laser Technology Co., Ltd., Wuxi 214000, Jiangsu , China
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    Figures&Tables (17)
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    References (148)
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    Figures & Tables(17)
    Diagram of laser-arc hybrid welding process[17-18]

    Fig. 1. Diagram of laser-arc hybrid welding process[17-18]

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    Reference statistical results under different classifications. (a) Countries; (b) years

    Fig. 2. Reference statistical results under different classifications. (a) Countries; (b) years

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    Multi-material steel-aluminum hybrid body of typical new energy vehicle

    Fig. 3. Multi-material steel-aluminum hybrid body of typical new energy vehicle

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    Typical welding defects of aluminum alloy. (a) Joint softening[45]; (b) pore[52]; (c) crack[53]

    Fig. 4. Typical welding defects of aluminum alloy. (a) Joint softening[45]; (b) pore[52]; (c) crack[53]

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    Microstructure and hardness distribution of fusion welded joints of heat treatable aluminum alloys. (a) Welding heat cycling during cooling[61]; (b) microstructure of each area of welded joint[61]; (c) microhardness distribution of typical laser-arc hybrid welded joints[66]

    Fig. 5. Microstructure and hardness distribution of fusion welded joints of heat treatable aluminum alloys. (a) Welding heat cycling during cooling[61]; (b) microstructure of each area of welded joint[61]; (c) microhardness distribution of typical laser-arc hybrid welded joints[66]

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    Analysis results of microstructure and properties of laser-arc hybrid welded joints of Al-Zn-Mg-Cu alloys[72]. (a) Nano indentation test results; (b) grain morphology of FQZ; (c) microstructure of FQZ

    Fig. 6. Analysis results of microstructure and properties of laser-arc hybrid welded joints of Al-Zn-Mg-Cu alloys[72]. (a) Nano indentation test results; (b) grain morphology of FQZ; (c) microstructure of FQZ

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    Microhardness distributions of Al-Mg alloy laser-MIG hybrid welded joints. (a) Low Mg alloy［48］；(b) high Mg alloy［47-48］

    Fig. 7. Microhardness distributions of Al-Mg alloy laser-MIG hybrid welded joints. (a) Low Mg alloy［48］；(b) high Mg alloy［47-48］

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    Mechanical properties of laser-arc hybrid welded joints of Al-Mg-Si alloys for vehicle use[80]. (a) Microhardness distribution；(b) mechanical properties

    Fig. 8. Mechanical properties of laser-arc hybrid welded joints of Al-Mg-Si alloys for vehicle use[80]. (a) Microhardness distribution；(b) mechanical properties

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    Effects of wire composition on mechanical properties of laser-MIG hybrid welded joints of Al-Mg-Si alloys[83]. (a) Strengthening mechanism of weld seam; (b) mechanical property

    Fig. 9. Effects of wire composition on mechanical properties of laser-MIG hybrid welded joints of Al-Mg-Si alloys[83]. (a) Strengthening mechanism of weld seam; (b) mechanical property

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    Influence of "O" shaped swing laser on weld solidification behavior[88]. (a) Traditional laser welding; (b) "O" shape swing laser welding

    Fig. 10. Influence of "O" shaped swing laser on weld solidification behavior[88]. (a) Traditional laser welding; (b) "O" shape swing laser welding

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    Typical keyhole pore morphology in laser-arc hybrid welds of Al-Mg-Si alloys[105]

    Fig. 11. Typical keyhole pore morphology in laser-arc hybrid welds of Al-Mg-Si alloys[105]

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    Mechanism of keyhole pore formation[111]. (a) Keyhole dynamic behavior; (b) schematic of pore formation; (c) profile photograph of weld

    Fig. 12. Mechanism of keyhole pore formation[111]. (a) Keyhole dynamic behavior; (b) schematic of pore formation; (c) profile photograph of weld

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    Principle of swing laser and its effect on weld pore[113-114]. (a) Schematic of swing laser technology; (b) laser-arc hybrid weld seam; (c) swing laser-arc hybrid weld seam

    Fig. 13. Principle of swing laser and its effect on weld pore[113-114]. (a) Schematic of swing laser technology; (b) laser-arc hybrid weld seam; (c) swing laser-arc hybrid weld seam

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    Suppression mechanism of keyhole pore at high oscillating amplitude and high frequency[104]. (a) High-speed images of keyhole dynamics; (b) process of melt filling cavity; (c) profile photograph of weld

    Fig. 14. Suppression mechanism of keyhole pore at high oscillating amplitude and high frequency[104]. (a) High-speed images of keyhole dynamics; (b) process of melt filling cavity; (c) profile photograph of weld

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    • Table 1. Chemical compositions of typical Al-Mg(-Mn) alloys (mass fraction, %)

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      Table 1. Chemical compositions of typical Al-Mg(-Mn) alloys (mass fraction, %)

      AlloySiFeCuMnMg
      5052≤0.25≤0.40≤0.10≤0.102.2‒2.8
      5182≤0.20≤0.35≤0.150.20‒0.504.0‒5.0
      57540.40≤0.350.100.502.6‒3.6

    • Table 2. Chemical compositions of typical Al-Mg-Si(-Cu) alloys (mass fraction, %)

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      Table 2. Chemical compositions of typical Al-Mg-Si(-Cu) alloys (mass fraction, %)

      AlloySiFeCuMnMg
      60630.2‒0.6<0.350.10.10.45‒0.90
      60050.5‒0.9<0.350.30.500.4‒0.7
      60090.6‒1.0<0.50.15‒0.600.2‒0.80.4‒0.8
      60100.8‒1.2<0.50.15‒0.600.2‒0.80.4‒0.8
      61110.7‒1.1<0.400.5‒0.90.15‒0.450.5‒1.0
      60220.8‒1.50.05‒0.200.01‒0.100.02‒0.100.45‒0.70
      60161.0‒1.5<0.5<0.2<0.20.25‒0.60
      60820.7‒1.30.50.10.4‒1.00.6‒1.2
      6181A0.7‒1.10.15‒0.50<0.25<0.40.6‒1.0

    • Table 3. Chemical compositions of typical Al-Zn-Mg(-Cu) alloys (mass fraction, %)

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      Table 3. Chemical compositions of typical Al-Zn-Mg(-Cu) alloys (mass fraction, %)

      AlloyZnMgCuSiFeZr
      70036.20‒6.600.68‒0.720.16‒0.200.120.200.15‒0.19
      71084.50‒5.500.70‒1.40≤0.05≤0.10≤0.100.12‒0.25
      70466.60‒7.601.00‒1.60≤0.25≤0.20≤0.400.10‒0.18
      70755.10‒6.102.10‒2.901.20‒2.000.400.500.10‒0.18
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    Xiaonan Wang, Xiaming Chen, Pengcheng Huan, Xiang Li, Qipeng Dong, Shuncun Luo, Nagaumi Hiromi. Review of Laser-Arc Hybrid Welding Process of Aluminum Alloys for New Energy Vehicles(Invited)[J]. Chinese Journal of Lasers, 2024, 51(4): 0402102

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    Paper Information

    Category: Laser Forming Manufacturing

    Received: Oct. 30, 2023

    Accepted: Dec. 13, 2023

    Published Online: Jan. 17, 2024

    The Author Email: Wang Xiaonan (wxn@suda.edu.cn)

    DOI:10.3788/CJL231337

    CSTR:32183.14.CJL231337

    Topics

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