Full-penetration laser beam welding is characterized by a weld seam whose depth equals the material thickness. It is associated with a stable capillary and is therefore widely used for welding of sheet metal components. The realization of lightweight concepts in car body production requires the application of high-strength aluminum alloys that contain magnesium as an alloying element, which significantly influences the evaporation temperature and pressure. This change of the evaporation processes influences the geometry of the capillary and therefore its absorptance. In order to quantify the influence of magnesium on the capillary, their geometries were captured by means of high-speed synchrotron X-ray imaging during the welding process of the aluminum alloys AA1050A (Al99.5), AA5754 (AlMg3) and AA6016 (AlSi1.2Mg0.4). The 3D-geometries of the capillaries were reconstructed from the intensity distribution in the recorded X-ray images and their absorptance of the incident laser beam was determined by the analysis of the reconstructed 3D-geometry with a raytracing algorithm. The results presented in this paper capture for the first time the influence of the magnesium content in high-strength aluminum alloys on the aspect ratio of the capillary, which explains the reduced absorptance in case of full-penetration laser beam welding of aluminum alloys with a high content of volatile elements. In order to improve the absorptance in full-penetration welding, these findings provide the information required for the deduction of new optimization approaches.
Friction modifier additive technologies play a crucial role in controlling friction and wear of lubricated tribological systems. Novel additives are usually evaluated using formulations of varying concentrations. It can be very difficult to understand the underlying mechanisms in those laboratory tests because of the interaction of base oil with the additives. It thus can be insightful to perform model experiments in a controllable atmosphere. This can be achieved for instance by integrating a tribometer into a vacuum system comprising in-situ surface analytical methods.In this work, a nitrogen containing organic friction modifier is adsorbed from the gas phase onto a Fe2O3 surface. Different coating thicknesses are prepared by varying the duration of the vapor deposition, so that the influence of the coating thickness on the friction behavior can be investigated. The chemical composition of the coated surfaces is also analyzed by coupling to an XPS photoelectron spectrometer.Contrary to the assumption that layers are formed, this friction modifier accumulates in droplets on the Fe2O3 surface. The number of droplets as well as the radii of droplets increase with evaporation time. The chemical composition of the additive does not change as a result of the gas phase deposition. In the friction tests, the smallest friction values are found for a very low coverage of droplets. For larger droplets, friction increases due to a capillary neck of additive that forms between the sliding surfaces and is dragged along during the friction test.Using gas phase adsorption of a nitrogen containing organic friction modifier it was possible to establish a correlation between droplet morphology and the friction behavior.
An equiaxed grain structure in a laser welded seam is beneficial. In current literature the material and process perspective are addressed separately. This paper combined the material and process perspective in one analytical expression in order to access a deeper understanding of the key parameters for an equiaxed solidification during laser beam welding. For this, the steady state model of Hunt for growth of equiaxed dendritic grains was combined with heat conduction calculations and nucleation theory. The derived analytical expression identified the minimum values of the welding parameters required for the growth of equiaxed dendritic grains and describe their interaction with the metallurgically given nucleation density. The theoretically derived analytical description agrees well with experimental results obtained with two different batches of EN AW-6016 over a wide-range of laser welding parameters. The analytical description summarizes the effects of nucleation processes, local solidification conditions and the influence of process parameters on the growth of equiaxed dendritic grains. Furthermore, the equation identifies the key alloy properties, which influence the required process parameter for an equiaxed solidification. For the first time, the full range of phenomena, including metallurgical and thermal effects, was merged in one analytical expression.
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