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<p>In this paper, 6082 aluminum alloy and DP980 dual-phase steel are taken as the research object, and the laser power, welding speed, defocusing amount, frequency, and duty cycle are selected as variables to study the effects of various parameters on the dissimilar alloy 6082-DP980 brazing or welding laser spiral joint, by selecting the best welding parameters to verify the best welding method. The microstructure and mechanical properties of the welded joint, heat-affected zone, and base metal were analyzed. The results showed that the joint strength is the highest and the best welding results were obtained; when using the defocusing amount of 0.75 mm, the duty cycle is 90%, the frequency is 5500 Hz, the power is 560 W, and the speed is 20 mm/s. Under the super depth of field microscope, the best parameter group showed brazing, brittle metal compound (IMC) is weak, and there is no macroscopic crack, while the control group showed fusion welding with an obvious IMC layer, large deformation, and many cracks. SEM observation showed that the IMC thickness of the optimized group was 4 ~ 15 µm, and the control group is much larger and has a wider diffusion of element. In the tensile test, the preferred group showed higher tensile strength and yield strength, and slightly lower plasticity; the strength of the control group is lower but the ductility is better. This study can guide the welding process behavior of the emerging laser spiral spot welding of aluminum-steel dissimilar metals in practical engineering applications.</p>

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Study on process parameter optimization and mechanical properties of laser spiral welding of aluminum-steel dissimilar materials

  • 期刊论文

  • 发表日期：

    2025年8月1日

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  • Nuo Cheng,
  • Shanglei Yang,
  • Qiubo Li,
  • Kuntao Liu,
  • Suqi Xue,
  • Bangguo Hu

摘要

In this paper, 6082 aluminum alloy and DP980 dual-phase steel are taken as the research object, and the laser power, welding speed, defocusing amount, frequency, and duty cycle are selected as variables to study the effects of various parameters on the dissimilar alloy 6082-DP980 brazing or welding laser spiral joint, by selecting the best welding parameters to verify the best welding method. The microstructure and mechanical properties of the welded joint, heat-affected zone, and base metal were analyzed. The results showed that the joint strength is the highest and the best welding results were obtained; when using the defocusing amount of 0.75 mm, the duty cycle is 90%, the frequency is 5500 Hz, the power is 560 W, and the speed is 20 mm/s. Under the super depth of field microscope, the best parameter group showed brazing, brittle metal compound (IMC) is weak, and there is no macroscopic crack, while the control group showed fusion welding with an obvious IMC layer, large deformation, and many cracks. SEM observation showed that the IMC thickness of the optimized group was 4 ~ 15 µm, and the control group is much larger and has a wider diffusion of element. In the tensile test, the preferred group showed higher tensile strength and yield strength, and slightly lower plasticity; the strength of the control group is lower but the ductility is better. This study can guide the welding process behavior of the emerging laser spiral spot welding of aluminum-steel dissimilar metals in practical engineering applications.