The use of 7000 aluminum alloys has an important role in future lightweight structures in the field of mobility due to the low density and high strength. However, these alloys can only be fusion welded to a limited extent because welding defects can rarely be prevented. For this reason, investigations are carried out to identify the most suitable welding parameters for two processes: laser beam and magnetic pulse welding. Herein, laser beam welding is successfully used to manufacture a roll‐formed and longitudinally welded pipe made of AA7075 and joined by magnetic pulse welding with a 3D‐printed lug‐tube made of AlSi10Mg. The fatigue strength of these pipe joints and of laser beam welded butt joint specimens is determined using load‐controlled fatigue tests. For the characterization of the specimens, cross sections are prepared and examined metallographically, which reflect the local weld seam geometry in the joining area. A fatigue assessment is made using linear‐elastic approaches. The reference radius concept is applied to map the influence of geometric notches on the fatigue strength, assuming linear‐elastic stress–strain behavior. It is shown that the recommended notch stress fatigue class FAT 178 (von Mises stress) can be applied for a safe and reliable fatigue assessment.
In this paper, the potential of directional ultrasonic wave superposition by moving sound generators for laser beam welding of high-strength steel alloys 1.5528 (22MnB5) is studied. Steel sheets of identical thickness and in form of tailored blanks were joined in butt joint configuration. The influences of the various excitation parameters of the moving sound generators on the ultrasonic coupling and their influence on the distribution of the AlSi coating components within the melting zone and the weld seam characteristics are investigated. Etched cross-sections, scanning electron microscopy, energy dispersive X-ray spectroscopy, and electron backscattering measurements were used as the investigation methods to determine the AlSi distribution in the weld as well as its microstructure. The results presented a series of experiments which show that a suitable superposition of ultrasonic waves by the moving sound generators lead to a more homogeneous distribution of AlSi particles in the melt as well as to a finer microstructure within the weld, which improves the mechanical–technological properties.
The present study provides an overview of previous studies on the welding of the AA7075-T6 aluminum alloy, followed by an investigation of the influence of short-time solution annealing on the mechanical properties of the weld. Conventional laser welding of Al-Zn-alloys leads to a low weld strength, which makes a post weld heat treatment (PWHT) favorable. The PWHT includes solution annealing, quenching and subsequent aging. For solution annealing, different holding times and cooling rates are investigated in this study. The focus of the investigation is on a short solution annealing time, which on the one hand is ecological and economically favorable and on the other hand offers great potential for inline heat treatments. The shortest solution annealing time of 10 s shows a significant increase in weld strength (joint efficiency of 72%), compared to the non-heat treated weld (joint efficiency of 52%). The microstructural analysis reveals that the cooling rate after solution heat treatment affects the formation of precipitates in the microstructure of the welded AA7075 alloy. Moreover, the enhancement of mechanical properties is related to the formation of Mg-Al-Cu and Mg-Zn rich precipitates.
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