Welding Characteristics of Laser-MIG Hybrid Welding of Arc-Welded Aluminum Profiles for High-Speed Trains

Du, Lingzhi; Yang, Zhibin; Wang, Xing

doi:10.3390/ma16010404

Cited by 5 publications

(2 citation statements)

References 26 publications

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“…MAG welding technology is used for manufacturing most of internal components of automobiles [3], [4]. However, traditional MAG welding is associated with problems such as high thermal input, poor welding efficiency, and serious joint softening [5]- [7]. In contrast to MAG welding, the hybrid Laser-MAG process combines the merits of both arc and laser, representing an innovative type of welding heat source.…”

Section: Introductionmentioning

confidence: 99%

An improved simulation of temperature field in Laser–low current

Xu,

Sun,

Han

et al. 2024

Preprint

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This study aimed to achieve efficient and precise connection of thin steel sheets for vehicles by analyzing the thermal process of Laser-MAG hybrid high-speed welding lap of thin galvanized steel sheets. A high-speed camera combined with an NI AD data acquisition system were used, and the transition behavior and electrical signals of low-current MAG and Laser-MAG hybrid welding were examined. The thin sheet MAG welding droplet transition method mainly comprised short-circuit transfer. During the short-circuit phase, the voltage decreased and the current increased sharply, forming a short-circuit liquid column. When current increased to a certain level, the liquid bridge burst, the droplets carried heat and kinetic energy to the weld pool, the arc voltage returned to a no-load state, and the arc was re-ignited. In the arcing phase, the current first decreased steeply and then slowly, while the voltage decreased slowly and smoothly. According to the different heat source characteristics of the arc combustion and short-circuit stages during short-circuit transition, a new MAG heat source for low-current short-circuit transition was developed. This study employed a double-ellipse heat source with different powers for the arc combustion stage as well as a uniform body heat source that considered the thermal and kinetic energies of the melt droplets for the short-circuit stage. The thermal input of low current MAG welding was described by double-ellipse and uniform body heat source periodic loading. Moreover, the laser exerted an attraction and compression influence over the arc during the hybrid welding, which promoted the droplet transfer. Therefore, based on the novel MAG heat source, a hybrid Laser-MAG heat source in the short-circuit transition mode was developed. The laser beam heat source was described using a three-dimensional column heat source, the arc attraction and compression by the laser were considered indirectly through distribution parameter tuning for the double-ellipse model, and the laser-promoted transition effects of the droplets were described through the cycle frequency alterations of a double ellipsoid and homogeneous heat source. this heat source model was used to determine the MAG welding and hybrid welding temperature fields. Using hybrid Laser-MAG welding, a weld with a high depth-to-width ratio and complete penetration was obtained. The weld geometry and weld pool length were determined through welding tests, and the test results coincided with the fusion line trend and shape of the weld obtained by simulation, proving the rationality of the developed heat source model.

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Section: Introductionmentioning

confidence: 99%

An improved simulation of temperature field in Laser–low current

Xu,

Sun,

Han

et al. 2024

Preprint

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“…When welding aluminum alloys using laser composite welding technology, it advantages include high efficiency, stability, and large melting depth, as well as fewer welding defects. 4–6 However, the problem of welding stress and strain has always been a hot topic for welding workers. 7–9 This is because the stress and strain during the welding process are the results of thermoelastic-plastic dynamic changes, which present different development states due to different heating and cooling.…”

Section: Introductionmentioning

confidence: 99%

Numerical simulation and experimental study of residual stress in dissimilar aluminum alloy laser composite welding

Chen,

Tang,

Xie

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part L:

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The study combined experimental and numerical simulation methods to investigate the distribution of residual stress in laser composite welding of dissimilar aluminum alloys 6063 and 5083. Using the Simufact Welding simulation software and a combined volume heat source, the distribution patterns of transverse and longitudinal residual stress fields at different welding speeds were analyzed. The blind hole method was used to test the residual stress after welding. The results showed that the use of a combined volume heat source model for heat source calibration yielded ideal results, and the thermal cycle curve was basically consistent with the simulation and experimental results of residual stress. As the welding speed decreased, the longitudinal residual stress of the parent material on both sides significantly decreased, while the transverse residual stress increased. The majority of tensile and compressive stresses on both sides of the 5083 and 6063 aluminum alloys decreased with a decrease in welding speed. The Von Mises equivalent stress indicated that the cooling process is the main stage for residual stress generation. When the welding speed decreased, the peak value of longitudinal residual stress on the 6063 aluminum alloy side decreased from 230 to 90 MPa, while that on the 5083 aluminum alloy side decreased from 304 to 150 MPa. These findings provide an important basis for controlling and reducing the residual stress and deformation of dissimilar aluminum alloy laser arc composite welded components.

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