Abstract In order to improve the welding efficiency and performance of aluminum alloy thin-walled structural components in the fields of projectiles, aerospace, and rail transportation, this paper studies the rapid laser self-fusion welding process, joint microstructure, and mechanical properties of 2 mm-thick 6082 aluminum alloy. The results show that through the exploration of process parameters, six groups of welds with good forming and no metallurgical defects are obtained, and the fastest speed reaches 6 m/min. The weld microstructure consists of a large amount of α-Al matrix and a small amount of Mg2Si phase. The hardness of the welded joint is 75.89 - 79.08 HV, reaching more than 84% of the base metal hardness; the average tensile strength is 224.5 MPa, reaching 81% of the base metal. This is due to the disappearance of the work hardening effect in the weld and heat-affected zone and the reduction of the Mg2Si strengthening phase caused by the evaporation and burn loss of low-boiling-point elements, resulting in the softening phenomenon. The tensile fracture morphology is a typical plastic fracture feature.
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