Effects of Laser Offset and Hybrid Welding on Microstructure and IMC in Fe–Al Dissimilar Welding
Abstract
:1. Introduction
2. Experimental Procedures
2.1. Material Properties and Weld Configuration
2.2. The Welding Procedures
2.3. Set-Up of the Welding Systems
2.4. Process Parameters
2.5. Metallographic Analysis and Mechanical Testing
- Keller’s solution (1 mL HF, 1.5 mL HCl, 2.5 mL HNO3, and 95 mL H2O) for aluminum microstructure.
- Vilella’s solution (1 g picric acid, 5 mL HCl, 100 mL ethanol) for steel microstructure.
3. Base Material Characterization
4. Laser Off-Set Welding Results
5. Laser Hybrid Welding Results
6. Conclusions
- The EDS/XRD analysis revealed the presence of FeAl2 in the laser welded joint.
- Full penetration and low defectiveness were obtained by laser offset welding. The interaction between liquid phases was restricted. Viscous forces were attenuated by optimizing the process energy balance. Moreover, the high cooling rate and low mix between the two metals enabled IMC layer growth, which was as thick as 6 µm. As stated in the literature, a thin IMC layer improves the mechanical properties of the weld. Brittle phases were detected but hot cracks were avoided.
- Hybrid laser-arc welding resulted less effective. In fact, an excessive weld crown was observed and the weld presented a lack of penetration. The process was instable because of the significant difference in thermal- and fluid-dynamic properties of the two metals, which compromised the keyhole stability. The interface was highly irregular and non-homogeneous, due to the action of the viscous forces.
Author Contributions
Conflicts of Interest
References
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Metal | C | Al | Cr | Mn | Mo | Mg | Ni | Ti | P | S | Si | Fe |
---|---|---|---|---|---|---|---|---|---|---|---|---|
AISI 316 | 0.08 | - | 18 | 2 | 3 | - | 14 | - | 0.045 | 0.03 | 1 | balance |
AA5754 | - | balance | 0.30 | 0.50 | - | 3.6 | - | 0.15 | - | - | 0.40 | 0.40 |
Metal | UTS (MPa) | YS (MPa) | E (GPa) | A% | HV | K (W/(m·K)) | TL (°C) | ρ (g/cm3) | c (J/(g·°C)) |
---|---|---|---|---|---|---|---|---|---|
AISI 316 | 580 | 290 | 193 | 50 | 178 | 16.3 | 1400 | 8 | 0.5 |
AA5754 | 230 | 80 | 68 | 17 | 62 | 147 | 600 | 2.66 | 0.9 |
Laser Power (kW) | Welding Speed (m/min) | Wire Feed Speed (m/min) | Current (A) | Voltage (V) | |
---|---|---|---|---|---|
Laser Offset Welding | 2.5 | 2 | - | - | - |
Hybrid Laser-MIG Welding | 3.42 | 2 | 1.2 | 80 | 24 |
Point No. | Al | Fe | Cr | Ni | Mg |
---|---|---|---|---|---|
P1 | 63.9 | 26.2 | 5.8 | 3.3 | 0.8 |
P2 | 71.37 | 23.43 | 3.6 | 1.6 | - |
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Casalino, G.; Leo, P.; Mortello, M.; Perulli, P.; Varone, A. Effects of Laser Offset and Hybrid Welding on Microstructure and IMC in Fe–Al Dissimilar Welding. Metals 2017, 7, 282. https://doi.org/10.3390/met7080282
Casalino G, Leo P, Mortello M, Perulli P, Varone A. Effects of Laser Offset and Hybrid Welding on Microstructure and IMC in Fe–Al Dissimilar Welding. Metals. 2017; 7(8):282. https://doi.org/10.3390/met7080282
Chicago/Turabian StyleCasalino, Giuseppe, Paola Leo, Michelangelo Mortello, Patrizia Perulli, and Alessandra Varone. 2017. "Effects of Laser Offset and Hybrid Welding on Microstructure and IMC in Fe–Al Dissimilar Welding" Metals 7, no. 8: 282. https://doi.org/10.3390/met7080282