Weldability evaluation and tensile strength estimation model for aluminum alloy lap joint welding using hybrid system with laser and scanner head

Abstract

Aluminum welding using a hybrid system with a laser and scanner welding head was performed under various welding conditions to verify the feasibility of applying an aluminum alloy to a car body. The experimental material was 5J32 aluminum alloy, and the laser power, welding speed, and laser incidence angle were used as the control variables. The weld bead shape and the tensile shear strength were evaluated in order to understand the aluminum lap joint weld characteristics. Analysis of variance (ANOVA) was conducted to identify the effect of the process variables on the tensile shear strength. Tensile strength estimation models using three different regression models were also suggested. The input variables were the laser power, welding speed, and laser incidence angle, and the output was the tensile shear strength. Among the models, the second-order polynomial estimation model had the best estimation performance, and the average error rate of this model was 0.058.