Abstract
Solidification cracks are among the most common defects observed in the remote laser welding (RLW) of 6xxx aluminium alloys. This study assesses a novel route to mitigating solidification cracking during RLW of the AA6005 alloy using alumina nanoparticles (Al2O3) within the fusion zone. The AA6005 sheets were electrodeposited using a CuSO4 bath containing 40 nm sized Al2O3 at different concentrations and deposition time. Characterisation of the welds was conducted using scanning electron microscopy (SEM), electron backscattered diffraction (EBSD), energy dispersive X-ray spectroscopy (EDS) and mechanical lap shear testing. The results show that the incorporation of Al2O3 nanoparticles can be effective in producing centreline crack-free welds. Furthermore, the microstructural analysis also reveals grain refinement by 65% with increasing of Al2O3 concentration from 1 to 5 g/L, this corresponds to a 10% improvement in shear strength of the welds, compared to a standard un-coated AA6005 alloy.
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