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<p>The analysis in this study is centered on the butt laser welding of 2.5-mm-thick sheets of 6063-T6 and 6082-T6 aluminum alloys. This type of joint is common in new energy vehicle bodies. It helps to reduce weight and combines the strength and toughness of both alloys. This investigation applies numerical simulation to examine the effects of laser heat input on the behavior of the molten pool’s flow. A rise in heat input is associated with a decrease in the molten pool’s stability. This phenomenon is evidenced by the retrograde and ascending movement of the liquid metal within the pool. The formation of columnar crystals is observed in the weld metal zone (WMZ) adjacent to the fusion line (FL) on both sides, while equiaxed crystals are primarily found at the heart of the WMZ. With increased heat input, the weld joint’s micro-hardness, ultimate tensile strength, and elongation undergo an initial increase and are followed by a decrease. The side of 6063-T6, characterized by a lower initial hardness, undergoes rapid solidification near the FL, leading to the formation of fine non-equilibrium grains. Due to their small size and high defect density, the mechanical strength is reduced, which is the site of fracture. Recommended for publication by Commission IV—Power Beam Processes.</p>

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Melt pool morphology, microstructure evolution, and mechanical properties of dissimilar aluminum alloy butt laser welding joints under different heat input

  • 期刊论文

  • 发表日期：

    2025年7月17日

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  • Shuwan Cui,
  • Ganli Mo,
  • Hongchen Li,
  • Xiaozhen Liu,
  • Chengyu Yang

摘要

The analysis in this study is centered on the butt laser welding of 2.5-mm-thick sheets of 6063-T6 and 6082-T6 aluminum alloys. This type of joint is common in new energy vehicle bodies. It helps to reduce weight and combines the strength and toughness of both alloys. This investigation applies numerical simulation to examine the effects of laser heat input on the behavior of the molten pool’s flow. A rise in heat input is associated with a decrease in the molten pool’s stability. This phenomenon is evidenced by the retrograde and ascending movement of the liquid metal within the pool. The formation of columnar crystals is observed in the weld metal zone (WMZ) adjacent to the fusion line (FL) on both sides, while equiaxed crystals are primarily found at the heart of the WMZ. With increased heat input, the weld joint’s micro-hardness, ultimate tensile strength, and elongation undergo an initial increase and are followed by a decrease. The side of 6063-T6, characterized by a lower initial hardness, undergoes rapid solidification near the FL, leading to the formation of fine non-equilibrium grains. Due to their small size and high defect density, the mechanical strength is reduced, which is the site of fracture. Recommended for publication by Commission IV—Power Beam Processes.