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<p>In the traditional single-mode Gaussian laser welding of aluminum alloy, the optimization of weld formation and the mitigation of porosity defects are significantly impeded by inherent challenges of non-uniform heat distribution and unstable molten-pool dynamics. This study proposes a synergistic strategy that combines a ring laser with filler wire to improve the formation and properties of aluminum alloy welded joints. The effect of microstructure and porosity on the mechanical properties of 6063 aluminum alloy welded joints was investigated. The microstructure of the welded joint analyzed by SEM&#xa0;and&#xa0;EBSD analysis indicated that the porosity of welded joints initially improves with the introduction of the ring laser, while the incorporation of filler wire significantly reduces porosity. With the ring laser and filler wire applied concurrently, a well-formed and defect-free weld can be achieved. At a ring laser power of 1000&#xa0;W, the maximum texture intensity of the weld seam (WS) is reduced by 28.13% for the introduction of filler wire. Under the combined effects of the ring laser and filler wire, the accumulation of geometrically dislocations is minimized. At a ring laser power of 500&#xa0;W, a maximum tensile strength of 177&#xa0;MPa can be achieved for welded joints of 6063 aluminum alloy produced by adjustable ring laser welding with filler wire. The findings should be useful for the development of adjustable ring laser welding of aluminum alloy.</p>

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Research on Microstructure and Mechanical Properties of 6063 Aluminum Alloy Joint Fabricated by Adjustable Ring Laser Welding with Filler Wire

  • 期刊论文

  • 发表日期：

    2025年12月2日

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  • Xiang Li,
  • Wenyu Pan,
  • Zhenhui Zhang,
  • Ruizu Liu,
  • Yanqiu Zhao,
  • Xiaohong Zhan

摘要

In the traditional single-mode Gaussian laser welding of aluminum alloy, the optimization of weld formation and the mitigation of porosity defects are significantly impeded by inherent challenges of non-uniform heat distribution and unstable molten-pool dynamics. This study proposes a synergistic strategy that combines a ring laser with filler wire to improve the formation and properties of aluminum alloy welded joints. The effect of microstructure and porosity on the mechanical properties of 6063 aluminum alloy welded joints was investigated. The microstructure of the welded joint analyzed by SEM and EBSD analysis indicated that the porosity of welded joints initially improves with the introduction of the ring laser, while the incorporation of filler wire significantly reduces porosity. With the ring laser and filler wire applied concurrently, a well-formed and defect-free weld can be achieved. At a ring laser power of 1000 W, the maximum texture intensity of the weld seam (WS) is reduced by 28.13% for the introduction of filler wire. Under the combined effects of the ring laser and filler wire, the accumulation of geometrically dislocations is minimized. At a ring laser power of 500 W, a maximum tensile strength of 177 MPa can be achieved for welded joints of 6063 aluminum alloy produced by adjustable ring laser welding with filler wire. The findings should be useful for the development of adjustable ring laser welding of aluminum alloy.