TY - JOUR

T1 - Using pulse shaping to control temporal strain development and solidification cracking in pulsed laser welding of 6082 aluminum alloys

AU - von Witzendorff, Philipp

AU - Kaierle, Stefan

AU - Suttmann, Oliver

AU - Overmeyer, Ludger

N1 - Funding information: The authors thank the German Research Association for Welding and Allied Processes of the DVS and the German Federation of Industrial Research Associations (AiF) for project funding and support (IGF-Nr. 17.487N).

PY - 2015/6/10

Y1 - 2015/6/10

N2 - High-speed observation of visible and infrared radiation was performed to measure the molten pool geometry, velocity of the solid-liquid interface and temperature profile during laser spot welding of aluminum. Hot cracking occurred at a late stage of solidification for the investigated laser pulse shapes. Hot cracking could be minimized by using a pulse shape with two distinct power levels and a final cooling slope to shut down the laser power. The drop of the laser power from the first to the second power level led to a high cooling rate and high interface velocity at the beginning of solidification. This drop in temperature and molten pool diameter released strains originating from thermal contraction and solidification shrinkage at the beginning of solidification, where spot welding is expected to have a higher ductility. After this initial high solidification rate, low interface velocities were observed during solidification within the second power level. The final solidification rate increased again as a function of the cooling time of the last laser pulse section. This type of solidification process was also found in metallographic microstructures with greater dendritic structures during solidification within the second power level. The strain release at the beginning of solidification minimized residual strains for the remaining solidification, so that crack-free and full penetration bead-on-plate seam welding with overlapping spot welds was possible.

AB - High-speed observation of visible and infrared radiation was performed to measure the molten pool geometry, velocity of the solid-liquid interface and temperature profile during laser spot welding of aluminum. Hot cracking occurred at a late stage of solidification for the investigated laser pulse shapes. Hot cracking could be minimized by using a pulse shape with two distinct power levels and a final cooling slope to shut down the laser power. The drop of the laser power from the first to the second power level led to a high cooling rate and high interface velocity at the beginning of solidification. This drop in temperature and molten pool diameter released strains originating from thermal contraction and solidification shrinkage at the beginning of solidification, where spot welding is expected to have a higher ductility. After this initial high solidification rate, low interface velocities were observed during solidification within the second power level. The final solidification rate increased again as a function of the cooling time of the last laser pulse section. This type of solidification process was also found in metallographic microstructures with greater dendritic structures during solidification within the second power level. The strain release at the beginning of solidification minimized residual strains for the remaining solidification, so that crack-free and full penetration bead-on-plate seam welding with overlapping spot welds was possible.

KW - Aluminum

KW - High-speed observation

KW - Hot cracking

KW - Pulsed laser welding

KW - Solidification

UR - http://www.scopus.com/inward/record.url?scp=84934916061&partnerID=8YFLogxK

U2 - 10.1016/j.jmatprotec.2015.06.007

DO - 10.1016/j.jmatprotec.2015.06.007

M3 - Article

AN - SCOPUS:84934916061

VL - 225

SP - 162

EP - 169

JO - Journal of Materials Processing Technology

JF - Journal of Materials Processing Technology

SN - 0924-0136

ER -