A Variance Analysis on the Porosity Distribution of Laser Welded A365 Casting with a Dual Beam Laser Under Various Oscillation Conditions

Abstract

Aluminum die casting facilitates the large-scale production of lightweight components. Complex and load-optimized geometries can be produced with high dimensional accuracy. However, the die-cast part has a high hydrogen content, which affects its weldability. In this study, laser welding with a combination of dual-beam and laser-beam oscillation was investigated, and the effect of welding factors on the penetration depth and pore formation were evaluated based on analysis of variance. The power distribution between the core and ring, the welding speed, oscillation width, and frequency were selected as the factors. All produced samples were analyzed based on their cross-sectional and X-ray images. The core power significantly influenced the penetration depth, and the oscillation effect was negligible for penetration depth but not for pore distribution. Core power and welding speed were the significant factors that caused the variation in pore distribution.