Effect of Laser Welding Parameters with Different Fillers on Solidification Cracking and Mechanical Properties of AA7075

Abstract

AA7075 is considered a ‘non-weldable’ alloy using fusion welding methods. In this study, laser welding is applied in pulse mode to weld 2 mm thick AA7075 aluminum alloy plates using different fillers. The aim is to identify the influence of welding parameters and fillers on solidification cracking susceptibility during laser welding using the circular patch test (CPT). X-ray radiography was used to detect and measure cracks in the CPT samples. Furthermore, the effects of the laser welding process and chemical composition of fillers on the accumulated crack length (CCL), microstructure, and mechanical properties were investigated. Moreover, the mechanical behavior and local deformation of the fusion zone (FZ) were investigated using micro-flat tensile tests with digital image correlation. The mechanical properties of the FZ were correlated with the CCL as well as with the microstructure of the FZ, which was investigated experimentally. The results show that the chemical composition of fillers and welding speed affect the CCL of solidification cracks. Changes in the microstructure were observed within the fusion zone, and the structure became uniform and finer with the formation of Mg2Si and magnesium-rich, copper, and zinc (η-phase) particles.