Welding of aluminium alloys with continuous wave Nd: YAG laser up to 5kW

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Aluminium alloys are used in a wide range of industrial applications because of their low density and good structural properties. Laser welding has been identified as a key technology which can offer distinct advantages over conventional joining techniques such as TIG, MIG, resistance spot welding, mechanical fasteners and adhesive bonding.The main problems associated with laser welding of aluminium alloys in general are the high the surface reflectivity, high thermal conductivity and volatilisation of low boiling point constituents. These and other material related difficulties have led to difficulties with weld and heat affected zone cracking, degradation in the mechanical properties and inconsistent welding performance.A programme was conducted to evaluate laser welding of aluminium alloys with a single laser spot, twin spot and with wire feed using a continuous wave Nd: YAG laser capable delivering up to 5kW at the workpiece. Laser and processing parameters were explored for producing butt, overlap and tee joints in 2xxx, 5xxx, 6xxx and 7xxx series aluminium alloys, but in this paper only 6xxx series results with wire feed are presented. Metallographical analysis and mechanical testing were conducted to assess the weld quality on AA6023-T6, AA6082-T6 and AA6181A-T4.Aluminium alloys are used in a wide range of industrial applications because of their low density and good structural properties. Laser welding has been identified as a key technology which can offer distinct advantages over conventional joining techniques such as TIG, MIG, resistance spot welding, mechanical fasteners and adhesive bonding.The main problems associated with laser welding of aluminium alloys in general are the high the surface reflectivity, high thermal conductivity and volatilisation of low boiling point constituents. These and other material related difficulties have led to difficulties with weld and heat affected zone cracking, degradation in the mechanical properties and inconsistent welding performance.A programme was conducted to evaluate laser welding of aluminium alloys with a single laser spot, twin spot and with wire feed using a continuous wave Nd: YAG laser capable delivering up to 5kW at the workpiece. Laser and processing parameters were explored for producing butt, overlap an...