Author Affiliations
School of Materials Science and Engineering, Southwest Jiaotong University, Chengdu 610031, Sichuan, Chinashow less
Fig. 1. Ultrasonic-assisted laser-MIG hybrid welding. (a) Schematic of equipment; (b) sectional view of partial assembly;(c) schematic of welding
Fig. 2. Dimension diagram of tensile specimen (unit: mm)
Fig. 3. Front and back sides (left) and macro-forming (right) of welded joints under different ultrasonic powers. (a1)-(a3) 0 W; (b1)-(b3) 130140 W; (c1)-(c3) 200210 W
Fig. 4. Structures of middle areas of joint welds and welds near fusion line at aluminum side under different ultrasonic powers. (a)(d) 0 W; (b)(e) 130-140 W; (c)(f) 200-210 W
Fig. 5. Microstructures of IMCs at steel/ aluminum interface and EDS line scanning results under different ultrasonic powers. (a)(b) 0 W; (c)(d) 130140 W; (e)(f) 200210 W
Fig. 6. Hardness distributions of welded joints under different ultrasonic powers
Fig. 7. Tensile strengths of joints after removing reinforcement under different ultrasonic powers
Fig. 8. Tensile fracture morphologies of specimens after removing reinforcement under different ultrasonic powers
Material | Al | Fe | Si | Cr | Ni | Mg | Mn | C |
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304 | - | Bal | ≤0.1 | 17.020.0 | 8.010.5 | - | ≤0.2 | ≤0.08 | 6061-T6 | Bal. | 0.7 | 0.40.8 | 0.100.35 | - | 1.0 | 0.15 | - | ER4043 | 81.83 | - | 16.96 | - | - | 1.31 | - | - |
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Table 1. Chemical compositions of base metal and welding wire (mass fraction, %)
Welding parameter | Value |
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Welding current(I)/A | 96 | Wire feeding speed (v) /(m·min-1) | 5 | Welding speed(vw) /(mm·s-1) | 8 | Flow rate of shielding gas Ar (R) /(L·min-1) | 25 | Ultrasonic power /W | 0-220 |
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Table 2. Parameters for ultrasonic-assisted laser-MIG hybrid welding
Location | Atomic fraction of Al /% | Atomic fraction of Fe+Cr+Ni / % | Atomic fraction of Si /% | Possible phase |
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A | 76.58 | 17.44 | 5.98 | Al8Fe2Si | B | 70.34 | 27.03 | 2.62 | FeAl3 | C | 78.40 | 13.86 | 7.74 | Al8Fe2Si | D | 67.97 | 25.55 | 6.48 | Al8Fe2Si | E | 63.00 | 32.29 | 4.71 | FeAl3 | F | 83.00 | 10.81 | 6.19 | Al8Fe2Si | G | 61.92 | 27.66 | 10.43 | Al8Fe2Si | H | 53.27 | 38.79 | 7.96 | Al8Fe2Si |
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Table 3. EDS point scanning analysis results at locations AH in Fig. 5
Area | Ultrasonic power of 0 W | Ultrasonic power of 130-140 W | Ultrasonic power of 200-210 W |
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HAZ | 47 | 49 | 52 | FZ | 81 | 83 | 91 |
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Table 4. Average hardness of each area of joints under different ultrasonic powers
Location | Mass fraction of Al /% | Mass fraction of Fe+Cr+Ni /% | Mass fraction of Si /% | Possible phase |
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1 | 81.01 | 11.46 | 7.53 | Al8Fe2Si | 2 | 72.80 | 22.8 | 4.39 | FeAl3 | 3 | 75.09 | 17.88 | 7.03 | Al8Fe2Si | 4 | 73.26 | 22.46 | 4.28 | Al8Fe2Si | 5 | 72.82 | 19.9 | 7.28 | FeAl3 | 6 | 71.78 | 24.98 | 3.24 | Al8Fe2Si | 7 | 66.83 | 29.56 | 3.61 | Al8Fe2Si | 8 | 74.85 | 18.44 | 6.70 | Al8Fe2Si | 9 | 73.27 | 21.66 | 5.07 | FeAl3 | 10 | 6.71 | 92.01 | 1.28 | Steel | 11 | 67.59 | 26.15 | 6.26 | Al8Fe2Si | 12 | 65.57 | 25.46 | 6.96 | Al8Fe2Si | 13 | 16.53 | 82.24 | 1.24 | Steel | 14 | 7.97 | 90.92 | 1.11 | Steel |
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Table 5. EDS point scanning analysis results at locations 114 in Fig. 8