Heat affected zone evolution in fine grained aluminum alloys during laser welding: Phase-field simulation and analytical investigation

Abstract

One of the biggest challenges in the welding of strengthened alloys by grain refinement is the grain growth phenomenon in the heat-affected zone (HAZ), which would result in the degradation of mechanical properties. The goal of this study is to comprehend the HAZ evolution in the fine-grained aluminum alloy during laser welding as a low heat input process. Spot laser welding of fined grain 1050 aluminum alloy revealed that grain growth and HAZ formation occurred in samples with 4 µm grain size, but no grain growth occurred outside of the fusion line (FL) in larger grain samples. The microstructure of HAZ was simulated using the numerical phase-field technique. The numerical model's findings demonstrated that a critical grain size (Dcr) for the base metal can be established, above which grain growth would not occur outside FL. To predict grain size distribution outside FL, an analytical model was also used. According to both models, as grain size increases, the HAZ width decreases, and above a critical grain size, no HAZ will form outside of FL. In spot welding, Dcr was independent of power density but for continuous welding processes, Dcr has a direct relationship with heat input per unit length of weld. Moreover, HAZ grain growth mainly occurred in heating step for both types of processes.