Skip to main content
SpringerLink
Log in

Effect of ultrasonic vibration on porosity suppression and columnar-to-equiaxed transition in laser-MIG hybrid welding of aluminum alloy

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Severe porosity and coarse columnar grain are prone to be formed in the laser-MIG welded joint of aluminum alloy, deteriorating the strength and ductility seriously. In this study, the ultrasound was designed to assist the laser-MIG hybrid welding of aluminum alloy, and the influence of ultrasonic vibration on weld formation, porosity, and microstructure was investigated. The weld depth was increased from 3.6 to 4.2 mm when external ultrasound with the pressure of amplitude transformer (PAT) of 132 N was used, indicating that the penetration ability of hybrid heat sources to the welded plate could be improved. It was attributed to the dispersion effect of ultrasound on arc plasma in the laser channel. The porosity rate was reduced from 5.66 to 1.05% under PAT of 132 N, because of the increase in escape velocity of bubbles. Moreover, the columnar to equiaxed transformation (CET) of grain in the weld was promoted and the width of columnar grain zone was gradually reduced with the increasing ultrasonic energy, owing to the breaking effect of cavitation and the stirring effect of acoustic stream. As a result, lower porosity rate and finer grain size led to improvement of the microhardness and the strength of weld by ultrasound. The study provides more guidance on employing ultrasound to improve the quality of welded joints.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16

Similar content being viewed by others

Data availability

All data are presented within the manuscript.

Code availability

Not applicable.

References

  1. Bi J, Liu L, Wang CY, Chen G, Jia XD, Chen X, Xia HB, Li XP, Starostenkov MD, Han B, Dong GJ (2022) Microstructure, tensile properties and heat-resistant properties of selective laser melted AlMgScZr alloy under long-term aging treatment. Mater Sci Eng, A 833:142527. https://doi.org/10.1016/j.msea.2021.142527

    Article  Google Scholar 

  2. Huang YM, Yuan YX, Feng YC, Liu JP, Yang LJ, Cui L (2022) Effect of activating flux Cr2O3 on microstructure and properties of laser welded 5083 aluminum alloys. Opt Laser Technol 150:107930. https://doi.org/10.1016/j.optlastec.2022.107930

    Article  Google Scholar 

  3. Hagenlocher C, Stritt P, Weber R, Graf T (2018) Strain signatures associated to the formation of hot cracks during laser beam welding of aluminum alloys. Opt Lasers Eng 100:131–140. https://doi.org/10.1016/j.optlaseng.2017.08.007

    Article  Google Scholar 

  4. Hu SD, Hou L, Wang K, Liao ZM, Zhu W, Yi AH, Li WF, Fautrelle Y, Li X (2021) Effect of transverse static magnetic field on radial microstructure of hypereutectic aluminum alloy during directional solidification. J Mater Sci Technol 76:207–214. https://doi.org/10.1016/j.jmst.2020.11.025

    Article  Google Scholar 

  5. Fan YY, Fan CL, Yang CL, Liu WG, Lin SB (2013) Research on short circuiting transfer mode of ultrasonic assisted GMAW method. Sci Technol Weld Joining 17(3):186–191. https://doi.org/10.1179/1362171811y.0000000058

    Article  Google Scholar 

  6. Chen C, Fan CL, Cai XY, Lin SB, Yang CL (2019) Analysis of droplet transfer, weld formation and microstructure in Al-Cu alloy bead welding joint with pulsed ultrasonic-GMAW method. J Mater Process Technol 271:144–151. https://doi.org/10.1016/j.jmatprotec.2019.03.030

    Article  Google Scholar 

  7. Xie WF, Huang T, Yang CL, Fan CL, Lin SB, Xu WH (2020) Comparison of microstructure, mechanical properties, and corrosion behavior of Gas Metal Arc (GMA) and Ultrasonic-wave-assisted GMA (U-GMA) welded joints of Al–Zn–Mg alloy. J Mater Process Technol 277:116470. https://doi.org/10.1016/j.jmatprotec.2019.116470

    Article  Google Scholar 

  8. Wu MX, Wu CS, Gao S (2017) Effect of ultrasonic vibration on fatigue performance of AA 2024–T3 friction stir weld joints. J Manuf Process 29:85–95. https://doi.org/10.1016/j.jmapro.2017.07.023

    Article  Google Scholar 

  9. Chen QH, Ge HL, Yang CL, Lin SB, Fan CL (2017) Study on pores in ultrasonic-assisted TIG weld of aluminum alloy. Metals 7(2):1–10. https://doi.org/10.3390/met7020053

    Article  Google Scholar 

  10. Zhu Q, Lei YC, Wang YL, Huang W, Xiao B, Ye YM (2014) Effects of arc-ultrasonic on pores distribution and tensile property in TIG welding joints of MGH956 alloy. Fusion Eng Des 89(12):2964–2970. https://doi.org/10.1016/j.fusengdes.2014.08.012

    Article  Google Scholar 

  11. Lei ZL, Bi J, Li P, Guo T, Zhao YB, Zhang DM (2018) Analysis on welding characteristics of ultrasonic assisted laser welding of AZ31B magnesium alloy. Opt Laser Technol 105:15–22. https://doi.org/10.1016/j.optlastec.2018.02.050

    Article  Google Scholar 

  12. Liu J, Zhu HY, Li Z, Cui WF, Shi Y (2019) Effect of ultrasonic power on porosity, microstructure, mechanical properties of the aluminum alloy joint by ultrasonic assisted laser-MIG hybrid welding. Opt Laser Technol 119:105619. https://doi.org/10.1016/j.optlastec.2019.105619

    Article  Google Scholar 

  13. Shcheglov PY, Uspenskiy SA, Gumenyuk AV, Petrovskiy VN, Rethmeier M, Yermachenko VM (2011) Plume attenuation of laser radiation during high power fiber laser welding. Laser Phys Lett 8(6):475–480. https://doi.org/10.1002/lapl.201110010

    Article  Google Scholar 

  14. Liu FY, Wang HQ, Meng XY, Tan CW, Chen B, Song XG (2022) Effect of magnetic field orientation on suppressing porosity in steady-magnetic-field-assisted aluminum alloy deep-penetration laser welding. J Mater Process Technol 304:117569. https://doi.org/10.1016/j.jmatprotec.2022.117569

    Article  Google Scholar 

  15. Sarabia R, Gallego-Juárez J, Rodríguez-Corral G, Elvira-Segura L, González-Gómez I (2000) Application of high-power ultrasound to enhance fluid/solid particle separation processes. Ultrasonics 38(1–8):642–646. https://doi.org/10.1016/S0041-624X(99)00129-8

    Article  Google Scholar 

  16. Gallego-Juarez JA (2010) High-power ultrasonic processing: recent developments and prospective advances. Phys Procedia 3(1):35–47. https://doi.org/10.1016/j.phpro.2010.01.006

    Article  Google Scholar 

  17. Wang L, Liu Y, Yang CG, Gao M (2021) Study of porosity suppression in oscillating laser-MIG hybrid welding of AA6082 aluminum alloy. J Mater Process Technol 292:117053. https://doi.org/10.1016/j.jmatprotec.2021.117053

    Article  Google Scholar 

  18. Nampoothiri J, Balasundar I, Raj B, Murty BS, Ravi KR (2018) Porosity alleviation and mechanical property improvement of strontium modified A356 alloy by ultrasonic treatment. Mater Sci Eng, A 724:586–593. https://doi.org/10.1016/j.msea.2018.03.069

    Article  Google Scholar 

  19. Li RQ, Li XQ, Chen PH, Guo X, Zhang M (2016) Effect rules and function mechanism of ultrasonic cavitation on solidification microstructure of large size high-strength aluminum alloy with hot top casting. Journal of Central South University(Science and Technology) 47(10): 3354–3359. https://doi.org/10.11817/j.issn.1672-7207.2016.10.010.

  20. Xu HB, Jian XG, Meek TT, Han QY (2004) Degassing of molten aluminum A356 alloy using ultrasonic vibration. Mater Lett 58(29):3669–3673. https://doi.org/10.1016/j.matlet.2004.02.055

    Article  Google Scholar 

  21. Li JW, Momono T, Tayu Y, Fu Y (2008) Application of ultrasonic treating to degassing of metal ingots. Mater Lett 62(25):4152–4154. https://doi.org/10.1016/j.matlet.2008.06.016

    Article  Google Scholar 

  22. Zhang SL, Zhao YT, Cheng XN, Chen G, Dai QX (2009) High-energy ultrasonic field effects on the microstructure and mechanical behaviors of A356 alloy. J Alloy Compd 470(1):168–172. https://doi.org/10.1016/j.jallcom.2008.02.091

    Article  Google Scholar 

  23. Wang F, Eskin D, Mi JW, Wang CN, Koe B, King A, Reinhard C, Connolley T (2017) A synchrotron X-radiography study of the fragmentation and refinement of primary intermetallic particles in an Al-35 Cu alloy induced by ultrasonic melt processing. Acta Mater 141:142–153. https://doi.org/10.1016/j.actamat.2017.09.010

    Article  Google Scholar 

  24. Yuan T, Kou S, Luo Z (2016) Grain refining by ultrasonic stirring of the weld pool. Acta Mater 106:144–154. https://doi.org/10.1016/j.actamat.2016.01.016

    Article  Google Scholar 

  25. Jian X, Meek TT, Han Q (2006) Refinement of eutectic silicon phase of aluminum A356 alloy using high-intensity ultrasonic vibration. Scripta Mater 54(5):893–896. https://doi.org/10.1016/j.scriptamat.2005.11.004

    Article  Google Scholar 

  26. Xu C, Sheng GM, Cao XZ, Yuan XJ (2016) Evolution of microstructure, mechanical properties and corrosion resistance of ultrasonic assisted welded-brazed Mg/Ti Joint. J Mater Sci Technol 32(12):1253–1259. https://doi.org/10.1016/j.jmst.2016.08.029

    Article  Google Scholar 

  27. Chen C, Fan CL, Cai XY, Lin SB, Yang CL, Zhuo YM (2020) Microstructure and mechanical properties of Q235 steel welded joint in pulsed and un-pulsed ultrasonic assisted gas tungsten arc welding. J Mater Process Technol 275:116335. https://doi.org/10.1016/j.jmatprotec.2019.116335

    Article  Google Scholar 

  28. Li SR, Mi GY, Wang CM (2020) A study on laser beam oscillating welding characteristics for the 5083 aluminum alloy: Morphology, microstructure and mechanical properties. J Manuf Process 53:12–20. https://doi.org/10.1016/j.jmapro.2020.01.018

    Article  Google Scholar 

  29. Chen R, Jiang P, Shao XY, Mi GY, Wang CM, Geng SN, Gao S, Cao LC (2017) Improvement of low-temperature impact toughness for 304 weld joint produced by laser-MIG hybrid welding under magnetic field. J Mater Process Technol 247:306–314. https://doi.org/10.1016/j.jmatprotec.2017.04.004

    Article  Google Scholar 

Download references

Funding

This work is supported by the Natural Science Foundation for Excellent Young Scholars of Shandong Province (ZR2021YQ30) and the Natural Science Foundation of Shandong Province of China (ZR2019PEE038).

Author information

Authors and Affiliations

  1. State Key Laboratory of Advanced Welding and Joining, Harbin Institute of Technology, Harbin, 150001, China

    Caiwang Tan, Bingxiao Xu, Fuyun Liu, Danyang Lin, Laijun Wu, Bo Chen & Xiaoguo Song

  2. School of Materials Engineering, Shanghai University of Engineering Science, Shanghai, 201620, China

    Yixuan Zhao

Authors
  1. Caiwang Tan
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Bingxiao Xu
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Fuyun Liu
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Yixuan Zhao
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Danyang Lin
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Laijun Wu
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. Bo Chen
    View author publications

    You can also search for this author in PubMed Google Scholar

  8. Xiaoguo Song
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

Caiwang Tan: validation, methodology, writing-original draft; Bingxiao Xu: methodology, data curation, writing; Fuyun Liu: conceptualization, writing—review and editing; Yixuan Zhao: conceptualization, revision; Danyang Lin: revision; Laijun Wu: revision; Bo Chen: revision; Xiaoguo Song: revision.

Corresponding authors

Correspondence to Fuyun Liu or Yixuan Zhao.

Ethics declarations

Ethics approval

The article follows the guidelines of the Committee on Publication Ethics (COPE) and involves no studies on human or animal subjects.

Consent to participate

All authors approve the manuscript to participate.

Consent for publication

All authors approve the manuscript to publication.

Conflict of interest

The authors declare no conflict of interest.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Tan, C., Xu, B., Liu, F. et al. Effect of ultrasonic vibration on porosity suppression and columnar-to-equiaxed transition in laser-MIG hybrid welding of aluminum alloy. Int J Adv Manuf Technol 122, 2463–2474 (2022). https://doi.org/10.1007/s00170-022-10034-4

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-022-10034-4

Keywords

Search

Navigation