Seventh Semester

SEMINAR (MEQ413)

EFFECT OF LASER BEAM ON

ALUMINIUM TO STEEL LASER
WELDING-BRAZING
Seminar by: Guided By :
BENZO M M Dr.DENIX M SEBASTIAN
S7,ME-B,18 ASST.PROFESSER
SJC20ME038 DEPT.OF.ME,SJCET PALAI

Department of
MECHANICAL ENGINEERING
CONTENTS
• Introduction
• Material selection
• Experimental setup
• Single laser beam
• Dual laser beam
• Result and discussion
• Weld formation
• Temperature histories and time interaction
• Interfacial microstructure
• Fracture behaviour
• Conclusion
• Reference

EFFECT OF LASER BEAM ON ALUMINIUM TO STEEL LASER WELDING-BRAZING 2

INTRODUCTION
• Al/steel hybrid structure

-Combine the benefits of both aluminum and steel

-Strong, lightweight, and energy-efficient structure

• Fabrication of Al/steel hybrid structure

-Uses laser technology to join aluminum and steel due to its larger speed,
small heating area and high automation

EFFECT OF LASER BEAM ON ALUMINIUM TO STEEL LASER WELDING-BRAZING 3

INTRODUCTION
• Interfacial intermetallic compound (IMC) thickness

• Significant impact on the properties of the joint.

-Thicker IMC layer can reduce the joint strength and fatigue resistance.

-Make the joint more susceptible to corrosion.

• IMC with the thickness of 1 μm - Most beneficial for the shear strength

• Joining of Al/ Steel (laser welding–brazing process)

-Done with different laser beam models

-Single laser beam, Dual laser beams.

EFFECT OF LASER BEAM ON ALUMINIUM TO STEEL LASER WELDING-BRAZING 4

MATERIAL SELECTION
• Selected materials

-DP590 dual phase steel and AA6061 aluminum alloy sheets.

Fig 1. Microstructure of a) DP590 dual phase steel, b) AA6061–T6 aluminum alloy.[1]

EFFECT OF LASER BEAM ON ALUMINIUM TO STEEL LASER WELDING-BRAZING 5

EXPERIMENTAL SETUP

Fig 2.Schematic diagram of laser welding–brazing system.[1]

EFFECT OF LASER BEAM ON ALUMINIUM TO STEEL LASER WELDING-BRAZING 6

CONTD..

• IPG fiber laser (YLR-5000)

• welding head (YW50)

• robot (KUKA)

• KD–4010 Fronius wire feeder

EFFECT OF LASER BEAM ON ALUMINIUM TO STEEL LASER WELDING-BRAZING 7

 Detailed process parameters. [1]
Adopted parameters Values

Laser beam models Single, Cross dual, Line-in dual

Laser power, W 2500

Welding-brazing speed, mm/s 8.33

Wire filling speed, mm/s 75

Defocused distance, mm +20

Flowing volume of protecting gas, L/min 15

EFFECT OF LASER BEAM ON ALUMINIUM TO STEEL LASER WELDING-BRAZING 8

SINGLE LASER BEAM
• Beam Characteristics:
-Vertically irradiated laser beam with +20 mm defocused distance.
-Defocused laser beam diameter: 0.56 mm.
-Angle between laser beam and wire feed nozzle: 60°.

Fig 3.Laser beam models[1]

EFFECT OF LASER BEAM ON ALUMINIUM TO STEEL LASER WELDING-BRAZING 9
DUAL LASER BEAM
• Single laser beam divided into dual beams using a splitting module.
• Keyhole formation prevented by defocused feature.

fig 4.Schematic diagram of energy distribution for dual laser beam.[1]

EFFECT OF LASER BEAM ON ALUMINIUM TO STEEL LASER WELDING-BRAZING 10

RESULTS AND DISCUSSIONS
WELD FORMATIONS

Weld appearances:
continuous and smooth weld were obtained.
• Single laser beam:
-filler material didn’t spread well on the steel surface, gaps in the
weld.
• In-line and cross dual laser beam:
-obtained good welds with the filler material filling the
brazing interface.

EFFECT OF LASER BEAM ON ALUMINIUM TO STEEL LASER WELDING-BRAZING 11

Temperature histories and time interaction

Fig 5. Temperature histories and time of interaction of different laser beam models:
(a) Single laser beam, (b) In–line dual laser beam.[1]

EFFECT OF LASER BEAM ON ALUMINIUM TO STEEL LASER WELDING-BRAZING 12

Temperature histories and time interaction

Fig 6. Temperature histories and time interaction of different laser beam models:
(c) Cross dual laser beam,(d) Time interaction at high temperature at middle regions.[1]

EFFECT OF LASER BEAM ON ALUMINIUM TO STEEL LASER WELDING-BRAZING 13

 INTERFACIAL MICROSTRUCTURE
• Single laser beam: thick layer of intermetallic compounds(IMC).
Top and middle regions had three layers and bottom region had
two layers.
• In-line dual laser beam: IMC is thinner , top had only two layers,
middle mixed with less thickness and bottom had one thin layer.
• Cross dual laser beam:IMC is thinnest here. All layers are
uniform under cross dual laser.

FRACTURE BEHAVIOUR
• Joints formed from cross dual laser beam is stronger than the
in-line dual laser beam, and single laser beam (single laser beam
is very brittle).
EFFECT OF LASER BEAM ON ALUMINIUM TO STEEL LASER WELDING-BRAZING 14
FRACTURE BEHAVIOUR

Fig 7. Load–displacement curves for three joints.[1]

.

EFFECT OF LASER BEAM ON ALUMINIUM TO STEEL LASER WELDING-BRAZING 15

CONCLUSION
• Dual laser beams arranged in a line or a cross will give good
welding result with well formed joints.
• Best and even material distribution of interfacial material was
achieved by the cross dual laser beam method.
• Strongest joints were obtained using the cross dual laser beam
method, due to well formed joint and the more consistent
distribution.
• Cross dual joint has the best performance in terms of tensile
strength and fractured displacement. This makes it a good
choice for applications where high joint strength and stiffness
are required.

EFFECT OF LASER BEAM ON ALUMINIUM TO STEEL LASER WELDING-BRAZING 16

References
1. Hongbo Xiaa, Wang Taoa, Liqun Lia, Caiwang Tana, Kaiping Zhanga Ninshu Ma
-Effect of laser beam models on laser welding-brazing Al to steel, 2020
2. Hongbo Xiaa, Liqun Lia, Ninshu Ma, Caiwang Tana, Jianfeng Gonga-lnfluence
of energy ratio on dual-spot laser welded-brazed Al/steel butt joint, 2020
3. Baiyun Yang, Danyang Lin, Hongbo Xia, Haoyue Li, Penghui Wang, Junke Jiao,
Xi Chen, Caiwang Tan, Liqun Li, Qian Wang, Ninshu Ma -Welding
characterization evolutions for dual spot laser welded-brazed Al/steel joint
with various spot configurations, 2022

EFFECT OF LASER BEAM ON ALUMINIUM TO STEEL LASER WELDING-BRAZING 17

 THANK YOU

EFFECT OF LASER BEAM ON ALUMINIUM TO STEEL LASER WELDING-BRAZING 18