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<p>Laser wire-filled butt welding was conducted on 2&#xa0;mm-thick 2A12 aluminum alloy sheets to quantify the coupled influence of laser power and welding speed on weld formation, solidification microstructure, mechanical performance, and corrosion behavior. Increasing heat input promoted grain coarsening, intensified Cu/Mg segregation along grain boundaries, and facilitated the formation of intermetallic compounds (Al<sub>2</sub>CuMg), accompanied by a slight decrease in hardness. Low heat input increased porosity, leading to reduced joint strength and deteriorated corrosion resistance. Under an optimized heat input of 1700 W–50&#xa0;cm/min, a well-formed weld with a balanced grain size and texture distribution was obtained, yielding a tensile strength of up to 352&#xa0;MPa and a ductile fracture characterized by deep dimples. Electrochemical measurements showed the highest charge transfer resistance (<i>R</i><sub>ct</sub>) under this condition, indicating the highest corrosion resistance. At constant laser power, increasing welding speed refined grains but increased porosity due to molten pool instability, resulting in decreased strength and corrosion resistance. Appropriate coordination of laser power and welding speed can suppress porosity and homogenize solute redistribution, contributing to enhanced mechanical strength and corrosion resistance of the joints.</p>

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Heat input dependent evolution of microstructure and mechanical and corrosion performance in laser wire-filled butt welding of 2A12 aluminum alloy

  • 期刊论文

  • 发表日期：

    2026年7月1日

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  • Jun-Jie Shao,
  • Dong-Ting Wu,
  • Peng Liu,
  • Chun-Ying Zheng,
  • Yong Zou

摘要

Laser wire-filled butt welding was conducted on 2 mm-thick 2A12 aluminum alloy sheets to quantify the coupled influence of laser power and welding speed on weld formation, solidification microstructure, mechanical performance, and corrosion behavior. Increasing heat input promoted grain coarsening, intensified Cu/Mg segregation along grain boundaries, and facilitated the formation of intermetallic compounds (Al2CuMg), accompanied by a slight decrease in hardness. Low heat input increased porosity, leading to reduced joint strength and deteriorated corrosion resistance. Under an optimized heat input of 1700 W–50 cm/min, a well-formed weld with a balanced grain size and texture distribution was obtained, yielding a tensile strength of up to 352 MPa and a ductile fracture characterized by deep dimples. Electrochemical measurements showed the highest charge transfer resistance (Rct) under this condition, indicating the highest corrosion resistance. At constant laser power, increasing welding speed refined grains but increased porosity due to molten pool instability, resulting in decreased strength and corrosion resistance. Appropriate coordination of laser power and welding speed can suppress porosity and homogenize solute redistribution, contributing to enhanced mechanical strength and corrosion resistance of the joints.