Feasibility Study of Handheld Laser Welding Technology for Small Thickness Aluminium Alloys

Abstract

Handheld laser welding with filler material is an interesting alternative for TIG and MIG/MAG welding in aesthetic parts of small thicknesses, due to its high versatility, speed of application, low deformability and aesthetic finish. The novelty of this study lies in the analysis of the feasibility of this process for welding aluminium alloys of low thickness (2mm), commonly welded by GTAW or GMAW processes. Due to its high sensitivity to heat, laser welding of aluminium alloys is always accompanied by defects such as porosity and cracks. In this work aluminium-magnesium alloy sheets (5754 H111) were joined using fillet weld, butt weld and cornice weld configurations. The appearance, microstructure, porosity and mechanical properties were analyzed through non-destructive and destructive tests. The results of the external aspect of the samples showed a very low distortion and deformation of the material; however, the macrographic analysis showed abundant internal porosity. In the case of the fillet and cornice welding this porosity was within the applicable standard, and in the case of the butt-welded samples, tensile tests results proved the validity of the process.