Defects in Laser Welding of Aluminum Alloys

Despite its high efficiency, speed, and significant cost reduction potential, laser welding also presents numerous drawbacks. Only by thoroughly understanding and resolving these defects can laser welding technology for aluminum alloys achieve broader application.

1. Porosity Defects

As mentioned earlier, moderate porosity maintains internal equilibrium in aluminum alloys. However, excessive gas bubbles create significant defects. Preventing large-scale porosity is challenging. When extensive porosity occurs, unstable gas bubbles migrate randomly within the alloy, readily causing cracks in welded areas. Therefore, eliminating porosity represents a major defect requiring breakthroughs in aluminum alloy laser welding technology.

2. Thermal Cracking Defects

Laser welding requires elevated temperatures and high energy density for rapid fusion, which can induce thermal cracks on the aluminum alloy surface, leading to weld failure. To address thermal cracking, scientists have employed filler materials during laser welding. However, this method often results in resource wastage and significant labor costs. Developing simpler solutions for thermal crack prevention represents another major challenge this technology must overcome.

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