Investigation of 6061 aluminum alloy pulsed laser welding based on the physical models for prediction of hot cracks

Subject Areas :

hossain ebrahimzadeh ¹ , hassan farhangi ² , seyed ali asghar akbari mousavi ³

1 - Ph.D Student, School of Metallurgy and Materials Engineering, College of Engineering, University of Tehran, Tehran, Iran
2 - Associated Prof., School of Metallurgy and Materials Engineering, College of Engineering, University of Tehran, Tehran, Iran
3 - Associated Prof., School of Metallurgy and Materials Engineering, College of Engineering, University of Tehran, Tehran, Iran

Received: 2018-10-01 Accepted : 2019-08-06 Published : 2019-10-23

Keywords: Aluminum Alloys, Hot Crack Physical Models, Pulsed Laser Welding, High Speed Camera, Fracture of Weak Grain Boundaries,

Abstract :

It is necessary to use a physical model for the relationship between welding parameters and hot cracks. These models are available in micro, meso, and macro-scale. In this research, a sheet of 6061 aluminum alloy was welded by a Nd:YAG laser machine. For the first time, the diameter of the dendritic arm spacing in the aluminum laser weld was measured and the results were compared with the solidification models. Contrary to the prediction of hot crack models, increasing the dendritic arm spacing, decreasing the solidification rate, and the reduction of the strain rate did not reduce hot cracking. However, based on the pre-existing models, preheating should reduce hot cracks, but inversely increases the amount of cracks. The images of high speed cameras and the assessment of crack surface by a field emission scanning electron microscopy showed that in pulsed laser welding, hot cracks will be created in three steps: 1) initiation 2) the first step of propagation 3) the second step of propagation. Propagation in the second step will occur in the newly solidified weak grain boundary of the weld metal. What is finally seen as a crack in the weld seam is the solidification and high temperature cracks and therefore, the models that are considered for continuous fusion welding are required to be modified based on the conditions of the pulsed solidification and melting and the fracture of weak grain boundaries after solidification should also be taken into account.

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