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<p>The increasing demand for lightweight structures in the automotive industry has promoted the use of aluminum alloys due to their superior strength-to-weight ratio and corrosion resistance. However, joining aluminum alloys by conventional resistance spot welding or laser welding remains challenging because of their high thermal conductivity, low laser absorption, and tendency for weld defects. This study aims to improve the performance of aluminum overlap welds in AA6014-T4 and AA6451-T6 alloys by employing Laser Seam Stepper (LSS) technology combined with laser beam oscillation. The influence of key process parameters—laser power, oscillation frequency, and welding speed—on weld geometry and mechanical properties was systematically investigated. Weld characteristics, including pitch distance, effective joint width, penetration depth, and faying interface melt zone, were analyzed and correlated with peak load. Increasing laser power from 2.6 to 2.8&#xa0;kW improved pitch distance by 4.5%, joint width by 16.3%, and penetration depth by 4.5%. Welding speed reduced penetration depth and joint width, while oscillation frequency decreased pitch distance but improved joint width. The maximum peak load of 4.34 kN was achieved at 2.8&#xa0;kW laser power, 20&#xa0;Hz oscillation frequency, and 50&#xa0;mm/s welding speed. A strong correlation between the faying interface melt zone and peak load enabled the development of an empirical model to predict joint strength. These results demonstrate that LSS with beam oscillation is a promising approach to enhance weld quality and mechanical performance in aluminum automotive structures.</p>

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Performance optimization and peak load prediction of dissimilar aluminum overlap joints using laser seam stepper

  • 期刊论文

  • 发表日期：

    2025年10月7日

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  • Yeo-Jin Jang,
  • Savyasachi Nellikode,
  • Eun-Been Gong,
  • Sunusi Marwana Manladan,
  • Tes Choi,
  • Oliver Kim,
  • Kevin Lee,
  • Dae-Geun Nam,
  • Yeong-Do Park

摘要

The increasing demand for lightweight structures in the automotive industry has promoted the use of aluminum alloys due to their superior strength-to-weight ratio and corrosion resistance. However, joining aluminum alloys by conventional resistance spot welding or laser welding remains challenging because of their high thermal conductivity, low laser absorption, and tendency for weld defects. This study aims to improve the performance of aluminum overlap welds in AA6014-T4 and AA6451-T6 alloys by employing Laser Seam Stepper (LSS) technology combined with laser beam oscillation. The influence of key process parameters—laser power, oscillation frequency, and welding speed—on weld geometry and mechanical properties was systematically investigated. Weld characteristics, including pitch distance, effective joint width, penetration depth, and faying interface melt zone, were analyzed and correlated with peak load. Increasing laser power from 2.6 to 2.8 kW improved pitch distance by 4.5%, joint width by 16.3%, and penetration depth by 4.5%. Welding speed reduced penetration depth and joint width, while oscillation frequency decreased pitch distance but improved joint width. The maximum peak load of 4.34 kN was achieved at 2.8 kW laser power, 20 Hz oscillation frequency, and 50 mm/s welding speed. A strong correlation between the faying interface melt zone and peak load enabled the development of an empirical model to predict joint strength. These results demonstrate that LSS with beam oscillation is a promising approach to enhance weld quality and mechanical performance in aluminum automotive structures.