Welding Aluminum Alloys To Other Alloys. Alibaba.com offers 11,044 laser welding of aluminum products. Crack free and porosity free butt weld of 2 mm thick Al6061 and Al5052. Each weld area created by a pulse cools quickly, which minimizes the amount of heat in the surrounding material, which in turn limits how hot the part might become, which in turn minimizes melting and distortion of the part. Aluminum alloys, are lightweight, possess good thermal and electrical conductivity, and are relatively inexpensive to work with. Materials that can be welded: Mild steel, carbon steel, stainless steel, aluminum, coated steel, copper, and titanium. The slight top bead undercut (concavity) can be eliminated by welding with an appropriate filler material such as Al4043 or Al4047 wire. More precise control of the weld pool for increased keyhole stability. Hydrocarbon residue on aluminum parts can generally be removed using acetone or alcohol based solvents. Of course, this by no means implies that laser welding is not an excellent choice for joining these materials. Call us at +1.631.495.1485‬ or use the links below. 209 W/m K) and low melting point (1,221°F/660.3°C) make it such that only fusion welding processes can be used to weld it. All other alloys can only be laser welded with the help of additives. Laser welding requires good joint fit up in regard to permissible gap and a low level of mismatch. The resulting weld quality is excellent. The welding copper to aluminium process uses our redENERGY 70W EP-Z Laser to create 3 spot welds, taking approximately 1 second, to produce an extremely strong hold between the Copper and Aluminium. About 11% of these are Laser Welders, 0% are TIG Welder, and 0% are Other Arc Welders. However, cleaned correctly and handled correctly, aluminum welds well with a laser. There are several different types of lasers that work well with aluminum, and often the use of a cover gas is prudent. Aluminum parts are frequently formed, sheared, sawed and machined prior to the welding operation. In micro-joining, adjusting comparatively small gaps is a major challenge. Continuous wave lasers typically feed at speeds of 25 to 100 inches per minute in order to not overheat the parts. Laser beam energy can be applied to the work piece either as a series of pulses, as a continuous beam, or in a laser stir weld configuration. These and other material related difficulties can lead to issues with weld and heat affected zone cracking, degradation in the mechanical properties, and inconsistent welding performance. However, for welds with deeper penetration in crack prone aluminum alloys, we’ve had a lot of success using our proprietary Laser Stir Welding technique. Fiber lasers are now widely used for welding of a very wide range of thicker metals. Welding in thin stainless steel plate, iron plate, aluminum plate and other metal materials can perfectly replace the traditional argon arc welding and electric welding … Good weld fixturing is necessary so that the laser beam can be placed accurately. This small heat affected zone is essential as aluminum’s high thermal conductivity tends to result in heat traveling throughout the work piece, either melting too much material or deforming the entire part. Mg, Zn). Another challenge of welding aluminum involves the formation of oxide film on the work surface. Misalignment and out-of-flatness of parts should be less than 25% of the material thickness. Contaminates can easily be transferred to a part and then pushed under the surface of the joint. One noteworthy application is laser edge-fillet welding of the aluminum doors on the BMW 7 Series luxury sedans (Figure 3). Clean all wire brushes and cutting tools frequently. Laser welding is widely used to join aluminum and its alloys. As little as a decade ago, laser welding aluminum was considered to … All rights reserved. Upon formation of a laser weld pool in aluminum, the shiny surface of the molten metal reflects much of the energy of the light beam. As stated earlier, cover gases are often required when laser welding aluminum. Laser welding uses laser as a high-energy density light source, which has the characteristics of fast heating and instant solidification. Oxidation issues can lead to contamination and porosity problems. Its relatively high thermal conductivity (approx. Sheared edges are acceptable provided they are straight and square. The process is very quick and clean with no oxide layers and a low electrical resistance. FIGURE 1 shows the effect of laser power (2–5.3kW), welding speed, and the gap between the sheets on weld porosity formation with a fillet edge welding configuration using a filler wire of AA4043 (5.3% Si) [7]. For round welds in aluminum, no gap can be tolerated unless inert gas coverage can be maintained over the entire weld area. It can also be combined with conventional welding processes, and can be used for soldering. A fit-up tolerance of 15% of the material thickness is desirable. GMAW (MIG) Services. Hydrocarbon contamination must be removed before abrading the surface to remove aluminum oxide. Goods quality welds can be achieved for the most alloys by cleaning the surfaces prior to welding and by providing adequate inert gas shielding of the weld pool. So, how do we ensure a reliable, robust laser process when welding aluminum alloys? This applies in particular for aluminum-silicon compounds. Avoid using compressed shop air to blow off debris from the area of the joint. Prudence dictates that aluminum parts which are to be welded should be pre-weld processed in a such a manner that minimal to no lubricants are used — sawing and machining of aluminum should be performed dry, if possible, and if not, the parts must be throughly cleaned. The laser welding cell paired with creative and unique part design methods give our customers the perfect tools to reduce cost and improve part quality. A wide variety of laser welding of aluminum options are available to you, such as warranty of core components, local service location, and key … Laser welding is widely used to join aluminum and its alloys. Nd:YAG (Neodymium: Yttrium-Aluminum-Garnet). Hydrocarbon contamination of aluminum during storage and preparation of the material can cause problems when welding. Manual welding processes, such as MIG and TIG, rely on operator skill and heat sinking to control these factors. The process is ideal for fast, clean welds. Major Challenge of Laser Welding. occurs when welding aluminum. This loss of energy and rapid heat dispersion in the work piece due to aluminum's high conductivity, require rather high power levels for welding. There are four main categories of lasers that are suitable for welding aluminum: All of these technologies are capable of producing high quality aluminum welds, and the method to be used is often dependent on operational costs rather than weld quality. The process works by focusing the laser’ beams light and energy on the target part and joint. Immediately afterwards, the continuous fiber laser welding technology also entered the market area of aluminum applications. The result was a range of laser and processing parameters that produce good quality welds for different aluminum alloys. Laser welding; Laser welding A laser beam can join metal in different ways – it can join workpieces at the surface or create deep weld seams. If a part must be blown off, use a bottled gas such as nitrogen or argon. The beam provides a concentrated heat source, allowing for narrow, deep welds and high welding rates. Welded medical devices, surgical tools, dental, plastics. Reflectivity is the most critical challenge with laser welding. The amount of heat applied and the location to which it is applied must be controlled very precisely. [l-3] Laser welding is a flexible high energy density welding process that produces welds of low distortion and a small heat affected zone through the use of easily automated and controlled equipment. Laser Stir Welding results in largely defect free joints, with no hot cracking, porosity or solidification cracks. The heat affected zone is minimized and weld penetration can range up … Aluminum has certain properties which make it more challenging to weld than other metals. Our engineering staff is your resource. Square edges and good fit-up are also necessary. We are experts north of Boston, Massachusetts in the field of welding steel and aluminum together, and other dissimilar metals or hybrids and alloys. A very important aspect to welding aluminum is how the joint is fabricated.  Special care in machining and assembly must be taken because aluminum is softer than most metals. When laser welding aluminum, only an aluminum-manganese alloy can be welded without filler material. The improvement is due to the filler material, which provides reinforcements to the weld zone by eliminating undercut from the top or root bead. However, due to the high reflectivity and good thermal conductivity of aluminum alloy and the shielding effect of plasma, some defects … Always use a new or recently cleaned stainless steel brushes to clean a joint.  Older brushes sitting around a work bench may contain oils and other contaminates.  Do not use brushes that have been used on other metals as metal flakes can be carried on the brush bristles, then imbedded under the surface of the aluminum during brushing. However, aluminum poses difficulty in welding because of three main properties: (1) thermal conductivity, (2) surface reflectivity to infrared and near infrared laser radiation, and (3) characteristics of the molten alloy including low viscosity and volatility of low boiling point alloying elements (e.g. The heat affected zone is minimized and weld penetration can range up to 0.25” in aluminum. With this in mind, there is keen interest in the use of laser welding to produce lightweight and economical vehicle structures in aluminium. If grinding cannot be avoided, use a course disk. However, aluminum poses difficulty in welding because of three main properties: (1) thermal conductivity, (2) surface reflectivity to infrared and near infrared laser radiation, and (3) characteristics of the molten alloy including low viscosity and volatility of low boiling point alloying elements (e.g. Alumi­ num is one of the easiest metals to penetrate with an electron beam. Diversity of alloys (see Table below for a summary of the main aluminum alloys). It was found that all the investigated alloys showed tendencies for porosity and solidification cracking,particula… Sales (+86)188 2695 0666 Email: ymqqs@ymlaser.com. However, with the evolution of high-power, good-beam-quality carbon dioxide (CO 2) lasers, and the advent of high-power, high-brightness solid-state, fiber-delivered lasers, coupling the energy into aluminum is no longer an issue. Generally, cover gasses are chosen on a per project basis, but a few general guidelines are: We’d be happy to quote your project, or help you work out any technical issues you might be running into. Date Published: Apr-2001 For welding heat sensitive components, such as electronics housings, using filler materials and welding with a pulsed laser is indicated. Addition of an appropriate filler wire reduces cracking in crack sensitive alloys such as the 2xxx and 6xxx series alloys. The process is frequently used in high volume applications using automation, as in the automotive industry. Higher mechanical strength aluminum-steel weld joints has been demonstrated with TIG, MIG, electronic beam, and laser welding. The process is ideal for fast, clean welds. Patterns can be programmed to compensate for large gaps in weld joints and other potentially problematic weld geometry problems. Material on the leading edge of the laser beam melts as the trailing edge cools. Choice of cover gas is generally dependent on the type of laser and its power rating as the use of the wrong cover gas can result in access plasma generation and/or changes to the properties of the welded materials. Modulation controls heating and cooling of the weld metal which reduces the freezing range of the weld metal and minimizes the tendency for solidification cracking. The laser welding machine has the advantages are simple operation, welding seam beautiful, fast welding speed and no consumables. Aluminum can be a difficult material to weld. Laser stir welding is a process in which a continuous beam laser is oscillated at a relatively high frequency, which causes a stirring action within the molten weld pool – hence the term “stir welding.” The result is a manipulation of the weld pool/vapor cavity, which changes some key characteristics of the weld. Laser-beam welding (LBW) is now considered to be a viable fusion joining process for aluminum with the advent of commercially available, stable, high-power laser systems. The near infrared 1070 nm wavelength has definite advantages over the incumbent CO 2 laser technology due to the lower reflectivity of metals at this wavelength. In this study, the influence of the laser powers on welding these dissimilar metals was taken into account. This joint configuration is especially suitable due to aluminum’s high shrinkage rate. Continuous wave laser welding is used for deep penetration welds, and is often referred to as keyhole welding. Metal inert gas (MIG) welding, also referred to as gas metal arc … Typical application fields for laser welding machines are the joining of steel, aluminum, copper or plastics. Clean the surface before welding – the main cause of porosity is the evolution of hydrogen gas during weld metal solidification. When cleaning a surface with solvents, use clean cloth such as cheese cloth or paper towels.  Do not use shop rags that may be contaminated with oil residue. Automated methods, such as Laser and Electron Beam, which use computers to control feed rate, power, and weld location, offer more precise and consistent weld quality. Avoid grinding process if possible. Improved control of the profile and geometry of the weld – as an example, joints can be designed with more width at the root of the weld, which can be very useful for Lap/Thru-/Blind welds. Al4043 or Al4047 wire be achieved than with pulsed laser is indicated applications, materials, and can welded. 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