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<p>Simulation of the mechanical behaviour of hybrid laser-arc welded joints is a critical issue in both academic and industrial communities. A key challenge lies in addressing the microstructural heterogeneity across different zones, which complicates accurate or even acceptable predictions. To overcome this challenge, a novel cross-scale methodology is proposed to precisely simulate the mechanical behaviour of laser-arc welded joints in aluminum 6061 alloy with filling material of 4043 alloy. To achieve this, the microscale plasticity of single crystals (SCs) with orientations of [10-1] and [31-2] is first investigated using micropillar compression testing. The results reveal that the yield strength of these SCs at small scales exhibits size independence, which contradicts previous literature. This phenomenon is attributed to strong solid solution strengthening and high dislocation density. Building on these findings, a micromechanics model is developed, integrating dislocation-based crystal plasticity theory and experimental results from micropillar compression testing This model successfully reproduces the mechanical behaviour of SCs at the microscale. Leveraging insights from crystal plasticity at small scales, a macroscale polycrystal model is constructed to simulate the mechanical behaviours of bulk materials. The predicted results for compressive and tensile mechanical behaviour at the macroscale demonstrate excellent agreement with experimental data. The physics and mechanisms governing the mechanical behaviour across scales are discussed in depth, drawing on results obtained from both experiments and simulations. Unlike traditional approaches that phenomenologically simulate the mechanical behaviour of welded joints, this novel methodology explicitly accounts for microstructural evolution. By bridging microscale and macroscale analyses, it provides new insights into the relationship between microstructure and mechanical properties in welded joints of aluminium 6061 alloy with filling material of 4043 alloy.</p>

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Bridging the gap between microscale and macroscale plasticity in hybrid laser-arc welded joints of aluminium alloy 6061: experimentation and modelling

  • 期刊论文

  • 发表日期：

    2025年7月11日

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  • Shaohua Yan,
  • Zhaosong Zhang,
  • Yan Zhu,
  • Qinghua Qin

摘要

Simulation of the mechanical behaviour of hybrid laser-arc welded joints is a critical issue in both academic and industrial communities. A key challenge lies in addressing the microstructural heterogeneity across different zones, which complicates accurate or even acceptable predictions. To overcome this challenge, a novel cross-scale methodology is proposed to precisely simulate the mechanical behaviour of laser-arc welded joints in aluminum 6061 alloy with filling material of 4043 alloy. To achieve this, the microscale plasticity of single crystals (SCs) with orientations of [10-1] and [31-2] is first investigated using micropillar compression testing. The results reveal that the yield strength of these SCs at small scales exhibits size independence, which contradicts previous literature. This phenomenon is attributed to strong solid solution strengthening and high dislocation density. Building on these findings, a micromechanics model is developed, integrating dislocation-based crystal plasticity theory and experimental results from micropillar compression testing This model successfully reproduces the mechanical behaviour of SCs at the microscale. Leveraging insights from crystal plasticity at small scales, a macroscale polycrystal model is constructed to simulate the mechanical behaviours of bulk materials. The predicted results for compressive and tensile mechanical behaviour at the macroscale demonstrate excellent agreement with experimental data. The physics and mechanisms governing the mechanical behaviour across scales are discussed in depth, drawing on results obtained from both experiments and simulations. Unlike traditional approaches that phenomenologically simulate the mechanical behaviour of welded joints, this novel methodology explicitly accounts for microstructural evolution. By bridging microscale and macroscale analyses, it provides new insights into the relationship between microstructure and mechanical properties in welded joints of aluminium 6061 alloy with filling material of 4043 alloy.